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[Lane]

I bought a set of CVO mufflers from someone off this forum. I ordered a set of Fullsacs and started to install them today but ran into a big problem. There weren't just 2 welds holding the baffles in but 5. Anyone else run into this? What do I do now? Weld them up?

[Lane]

Another pic

[Boatman]

Are you sure you have the CVO mufflers with the 4" shells?

[Lane]

Part number 64768-09. You tell me.

[igofar]

It looks like the piece with the 3 spot welds(front) of the baffle is supposed to stay in the muffler.
The baffle has a flared front end that is "supposed to" slip on and off of that piece.
It seems the baffle was really stuck on the end and instead of slipping off, it waited for you to get your biggest hammer and tore the welds off.

Not your fault but it is your problem.....

You will need to separate the two pieces and somehow weld the little front piece back into the muffler.

Spray LOTS of WD40 in the other one and let it sit until you figure out how to remedy the first one.

Sorry about your luck,

Brad

[Dan_Lockwood]

I bought a set of CVO mufflers from someone off this forum. I ordered a set of Fullsacs and started to install them today but ran into a big problem. There weren't just 2 welds holding the baffles in but 5. Anyone else run into this? What do I do now? Weld them up?

I seem to remember somewhere that either Jim Kerr with his excellent "how to" article, or someone else said that you need to be careful when you drive out the baffle from the stock muffler.  You can very easily drive on the piece that stays into the front of the muffler. 

After looking closely to your picture, it appears that you were driving on the "must stay in the muffler" piece and not the baffle itself.

I've not done this modification myself yet, but the driver may have to go down to the section inside the baffle that allows some force to be applied.

At this point if you just plan on re-welding the end back into the muffler, I'd separate the old baffle from the end piece and put it on the end of the new Fullsac baffle and push it back into the muffler until it lines up and then re-weld it in place.  I would think a bit of good high temp silver and the heat shields will keep it out of sight for you.

Good luck with the repair.

       

[Lane]

My bad! Ever have one of those days?
Thanks for the info. Just my luck. I had a big round wood dowel down inside the inlet to pound on, but it was just going through and not pushing the baffle out. Then I got this great idea to get a socket down in there to hit.

I guess I'll do like you said and try to weld the one piece back in.

I'll be the poster child for what not to do.

[Fullsac Performance]

Oh Boy!

Just got off the phone with Lane. Great guy! A little heavy handed maybe. Lesson here, never use anything larger than 1.25 to remove the baffles. It may get caught on the inlet piece that holds the cores in place. Hammer size can also become critical when a big boy like Lane is swinging it! Lane has tig welder and we have disused the path to recovery.
Pictures to follow. No pressure Lane. Keep us posted.

Steve

[dartman]

I bought a set of CVO mufflers from someone off this forum. I ordered a set of Fullsacs and started to install them today but ran into a big problem. There weren't just 2 welds holding the baffles in but 5. Anyone else run into this? What do I do now? Weld them up?

Wow, Ive repaired a few but none that completely ripped out, the baffle has a tapered end , ive never seen one really stuck tight enough to rip a spot weld, you had to be hammering directly against the inlet reciever pipe stub, in the future If you drill through a 4X4 with a 2 in hole to accomodate the end pipe, once you have cleaned out the two outlet welds insert the tail into the hole and just drop the outlet against the wood, the inertia will slide the baffle to the end without putting anything inside the inlet, Ive done dozens that way only takes a few minutes, the first one I did I got a broom handle stuck so I decided there had to be a better way.

[49445CVO]

Lane,

   Man I feel for ya but I do have to admit that is was a great read.  It is 2 a.m. here and I am quite slap happy and to read this made my day.  I have been having alot of these days lately and to see I am not the only one makes me feel human and not alone.  I can remember the first time I removed my windsheild and replaced it with a smaller one.  I was tightening up the three screws and popped all three out of the inner fairing. What a mess! I messed up the holes that the brass fittings go into and when I bought the replacement ones for the dealership and tried to install them they would not stay in.  I was getting out the super glue to find that it did not want to work.  Then the JB Weld only to find a little is different in my book because I thought I used a little until it filled the threaded brass fittings and needed to be drilled out.  Well this could go on and on but I wanted to tell ya my thought are with you.

Hope it all works out,

Topper

[warwick]

Hi. Got an 06 type of CVO mufflers with cats in them.

Not trying to hijack thread, but could someone please tell me how to proceed when applying the wooden dowel to punch out OEM baffle? All I see when peering down the inlet is the cat, and I have no idea of the exact location of OEM baffle. So where exactly to punch? In the center? And what size dowel? Flat or rounded?

Warwick   

[DakotaZeb]

Warwick,

Look for Jim Kerr's post and pictures on doing the Fullsac conversion.  That should help you a lot.  Also look at Fullsac's post above where he indicated using a 1.25" dowell/pipe to help force out the old baffle.

FYI, the cat is in the baffle.  Also remember you have grind down the two spot welds on the rear of the baffle before you try to use any force to remove the baffle.

Zeb

[charles05663]

Well Lane,

Look on the bright side.  At least this happened to a set of mufflers you bought and not the ones that came with your bike.  Otherwise, you would be out of a ride.  No down time, just frustration. 

[Boatman]

Hi. Got an 06 type of CVO mufflers with cats in them.

Not trying to hijack thread, but could someone please tell me how to proceed when applying the wooden dowel to punch out OEM baffle? All I see when peering down the inlet is the cat, and I have no idea of the exact location of OEM baffle. So where exactly to punch? In the center? And what size dowel? Flat or rounded?

Warwick   

I took an 1 1/4" socket and 12" extension and tapped on the converter-not the ring you see from the inlet end.  Once your welds are cut on the outlet end, tap the old baffle inward 1/4" so you can grind the rest of the welds off the muffler shell, then pull or drive the baffle loose.

[Lane]

All welded up and sounding good. I had to really struggle a bit to get the piece off the old baffle as it was good and smooched up a bit. After the seperation, I pounded on it a bit with it over a large pipe about the right size to get it reasonably round and straight again. Used the new Fullsac baffle as a guide to get that piece into the right location and TIG welded through the holes with stainless wire.

The other muffler came apart very easily compared to the first one. If I had done that one first I would have known what to do with the "stuck" one. Oh well, 50/50 chance.

Glad I was able to give some people some comic relief. Everyone plays the roll once in a while.

I do love the sound. In fact I'm now wondering how the monster ovals would sound with Fullsacs installed. I may be trying that one out in the future.
Thanks Steve for a great product.