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[Reds]

good job and good luck !

[HOGMIKE]

I started last Saturday.
Day one removed the mufflers cut the welds!  WOW that carbide bit is the bomb!! Very easy!
Best advice I got is go slow take it easy.  My advice is get ready and without cutting place your bit on the weld make sure you have room and you are comfortable.  Then when you do start cutting do it like you are petting your dog very soft and easy.  I dropped the muffler on a pile of rags on cardboard to move the baffle forward then clean up the rest of the weld.  Still it was hard to remove it.  I used a slide hammer and it came out but it didn't just slide out.  I drilled the hole working my way up to 1/4" with about four or five bits, piece of cake.  The FullSac baffles slide in I used a piece of wood to aligned the tubes to get it to slide in that last 1/4 inch. and bolted it in.
I would like to see that fastener that looks like a rivet!  If you are reading..please send a pic and info.
Day 2 Sunday
I removed the exhaust system...while keeping an eye on the Broncos whoop up on the KC Chiefs and deal with the phone calls from my friends about the game.  Broncos best game in years..and I am in the garage *BS...
The FullSac X pipe fit right in there.  I did this work on my lift ATV type good lift but not a mechanics lift.  I got it all together and cleaned up that evening.  I did start it Oh Yeah it sounds different!  I only ran it about 20 sec when I twisted the throttle I didn't like the way the bike torqued on the lift so I shut it down pretty quick.  I need install the the Master Tune when I get back home I am on the road working, and the weather should be good for a test ride!!
When I installed the softwear on my computer it put about four or five icons on my desk top.  I am not sure where to start with this program.  Steve send me a map its at home on that computer.  I hope this is easy.  Anything I need to know about running this?  I do know to save my configuration before I download the new one.
RedEagle
ps i took pis if anyone wants to see but Jim deserves credit for the procedure!
Thanks Jim Korr

Just take your time and read through the instructions. Once you figure it out, it only takes a minute or two to change/load maps.
 

[ssls6]

I started last Saturday.
Day one removed the mufflers cut the welds!  WOW that carbide bit is the bomb!! Very easy!
Best advice I got is go slow take it easy.  My advice is get ready and without cutting place your bit on the weld make sure you have room and you are comfortable.  Then when you do start cutting do it like you are petting your dog very soft and easy.  I dropped the muffler on a pile of rags on cardboard to move the baffle forward then clean up the rest of the weld.  Still it was hard to remove it.  I used a slide hammer and it came out but it didn't just slide out.  I drilled the hole working my way up to 1/4" with about four or five bits, piece of cake.  The FullSac baffles slide in I used a piece of wood to aligned the tubes to get it to slide in that last 1/4 inch. and bolted it in.
I would like to see that fastener that looks like a rivet!  If you are reading..please send a pic and info.
Day 2 Sunday
I removed the exhaust system...while keeping an eye on the Broncos whoop up on the KC Chiefs and deal with the phone calls from my friends about the game.  Broncos best game in years..and I am in the garage *BS...
The FullSac X pipe fit right in there.  I did this work on my lift ATV type good lift but not a mechanics lift.  I got it all together and cleaned up that evening.  I did start it Oh Yeah it sounds different!  I only ran it about 20 sec when I twisted the throttle I didn't like the way the bike torqued on the lift so I shut it down pretty quick.  I need install the the Master Tune when I get back home I am on the road working, and the weather should be good for a test ride!!
When I installed the softwear on my computer it put about four or five icons on my desk top.  I am not sure where to start with this program.  Steve send me a map its at home on that computer.  I hope this is easy.  Anything I need to know about running this?  I do know to save my configuration before I download the new one.
RedEagle
ps i took pis if anyone wants to see but Jim deserves credit for the procedure!
Thanks Jim Korr

I would love to see pictures (rknipe @ gmail dot com).  What carbide grinding bit did you use?


Thanks,
Richard

[HOGMIKE]

I would love to see pictures (rknipe @ gmail dot com).  What carbide grinding bit did you use?

Thanks,
Richard

I've done quite a few sets here, used a cheap Harbor Freight die grinder and this bit!
Works like a charm!

[HOGMIKE]

Bit:
Don't remember where I got it, probably our local Ace hardware.

[ssls6]

Thanks friend.  The pictures are great.

[RedEagle]

Update!
I saved my ECM configuration and loaded in Steve's FullSac TTS configuration.

WooooHoooo
Started right up and idled at 1200 to 1300 RPM cold.  After a good warm up took it for a spin.
Hey those heated grips and seat are nice..!!!
Bike sounds Very Good!!  and the torque is Very noticeable coming off the line and thru the gears.  I love the down shifts it reminds me of my Road King.  It ran Great!!
I can't wait to put more miles on it.
For those of you worried about the 2" baffles being to loud don't worry this is the ticket sounds Great not obnoxious at all.
I only put on about 10-15 miles the temps were in the 30's. 
Thanks to you guys I never would heard of FullSac..!!
Thanks to Steve and Cammy..!!

[RedEagle]

My pics. of the exhaust change.
Two of the clamps that need to be removed or loosen.

[RedEagle]

This is the tool I bought. Die Grinder $27-30
Carbide barrel shaped bit.  $24.

[RedEagle]

This baby cuts like crazy!!!!

[RedEagle]

My setup for cutting.
Good light.
Vise not tight but holds well.
Get comfortable before cutting then cut in nice easy strokes, I went right to left like painting strokes.

[RedEagle]

Here is the bad boy that must be cut.
Update.  Here you can see the weld is cut.
Notice the ring showing that I pushed the baffle forward to clean up the remaining weld before removing the baffle.  I droped the whole mullfler on to a padded cardboard with rags to push the baffle forward.
When you see this ring your weld is CUT lose!

[RedEagle]

Old vs New!
One out one to go!

[RedEagle]

Look at the old baffle.
Notice how the gases go left to right, then have to do a 180 turn and back to the inlet of the final exhaust pipe.

[RedEagle]

This is what it looks like in muffler.
I left this packing alone and installed the FullSac baffle next.
I found a wood dowel was needed to align them so the baffle would slide all the way in.
no force is need just get it lined up.