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[anasacuta]

Thanks to everyone here for all the great threads to help me do this job myself.

Fullsac X-pipe, 2" baffles, and TTS tuner.

This job took me about 8 hours, including two 45 minutes delays for trips to the dealer. The first trip was to get a new header gasket, I managed to mangle one trying to manipulate it into the front head. The second trip was for a new crossover pipe gasket which I also managed to mangle trying to fit the crossover back together. It was a very tight fit and the more I pushed, it created a shoulder in the gasket. So, I tried to remove it so I could spread the opening (there a re 4 slots on the pipe) and it didn't go so well. No problem with the new gasket...went right together and only cost $4.29. I would recommend having one on hand for those doing this job. A spare header gasket doesn't hurt either.  

The grinding on the baffle welds was a PITA, then actually getting the baffles out was more of a PITA. I found that pounding the whole muffler down onto a piece of carpet was the best way to get things moving in the right direction.

The TTS part was easy (I am a computer guy by trade). Saved my factory map, then uploaded the map Fullsac sent.

The bike sounds exactly like I had hoped it would. Not loud, but louder, and has that Harley low tone rumble I was looking for. Definitely less heat. Definitely more power. I couldn't be happier.

[1sharprdkg]

Well you like the results and only two extra trips to the dealer...I say thats a win! win! Good job! I like my Fullsac baffles too!

[Buy early]

Gotta love it when a plan comes together! Mod on.

[mark]

Grinding the baffle welds is a PITA...but worth it.  Congrats.

[Jackhd]

 :orange:sounds great   Do u think I should get those gaskets myself I am also doing it myself also.

[RedEagle]

Wha-Hoooo !!  Great..!!!
One of the best lessons of mechanics is be patient!! keep trying and you can not Stop until it is done right, even if you have to do it again, and in some cases again!
I think this the ZEN part

[anasacuta]

:orange:sounds great   Do u think I should get those gaskets myself I am also doing it myself also.

Your call, you may not need them, but if I were doing it again, I would spend the 10 bucks at the dealer up front and save myself the frustration of having to drop everything and get in the cage, make the trip to the dealer, all the while watching all the other bikes out on the road on this beautiful, sunny 75 degree day. Really pissed me off having to go there TWICE.

[Jackhd]

Thanks I will go tommorrow and get those gaskets.   Is your bike now really alot louder then stock?    Do you think your neighbors wil notice the sound increase?

[anasacuta]

Thanks I will go tommorrow and get those gaskets.   Is your bike now really alot louder then stock?    Do you think your neighbors wil notice the sound increase?

Yes...louder, but not considerably, it does have a deeper tone. To me it just sounds right. Will my neighbors notice the difference? As long as I am not cranking it up to the +3000 RPM, I doubt it.

[muddypaws]

Changed out the baffles last night. Today the X pipe and load the tuner. Can't wait to hear her and go for a ride.

[jcd520]

Here is a tip for those of you who don't already have these tools.

To remove the stockbaffles without removing the mufflers.  First , remove the end caps from the mufflers. Use an air dremel with a metal cutting die-------I got mine from the snap on man--------they are expensive but well worth it. The one I use is kind of cone shaped.
 I grind out the two welds(takes a total of about 5 minutes) then carefully use a large punch  or piece of  wood and knock the baffle in about an 1/8th of an inch , then grind out the slag where the welds were , also use some emery cloth to make it smooth and clean all the way around the inside of the muffler.Take your time and don't grind through the muffler wall as these metal tools are quite aggressive. Then I use a rod about 5/16 in diameter with a 90 degree bend on both ends and slipped one end into the stock baffle and turned it so it would hang on the pipe inside and just basically pulled the baffle out. You can tap on the bent other end of the rod if necessary like a jerk hammer if it needs it. Measure 1.5 inches in from the bottom of the muffler, drill your 1/4 inch hole and install the fullsac baffles, put in the bolts, reinstall the end caps and you are done. The whole process takes about 45 minutes and you don't have to remove the mufflers. If you are installing an x pipe or other product you have to remove the mufflers anyway, but I have changed out baffles for several folks that have catless headpipes and I do it this way all the time.

[muddypaws]

After changing out the baffles and installing the bolt from Fullsac I noticed the bolt looks like crap when looking at the back of the bike.  My plan is to install a chrome button head bolt. I should have drilled from the outside and I should have covered it up with the heat shield. Live and learn. It will be a 5 min fix.

[jcd520]

If you put the bolt in from the bottom  you shouldn't even be able to see the bolt head after the endcaps are back on but I use a chrome button head bolt on my installs as well . Just habit I guess. A local hardware store here has all that stuff in stock.

[Falcon 2000]

I removed the stock exhaust today. I removed the baffles and have everything ready to go back on as soon as UPS runs tomorrow. X-pipe, 2" baffle and TTS tuner.
Also while the head pipes are off, adding the 1" floorboard extenders. Should be riding before sundown tomorrow.

[muddypaws]

After a 180 mile ride I decided to put the insulation back in the mufflers. It was just too loud for my taste.Now when I'm cruising it has a nice rumble and when I get on her it's still nice and loud.  I got two nice chrome button head bolts and replaced the ones from Fillsac. I'm real happy with the setup.