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I love my Boom cans and the way my bike sounds and runs! Yesterday I rolled the Angry Bird out and fired it up and I heard a sound like a heat shield was about to fly off! Since I just started it I went around putting my hands on the pipes looking for the rattle. Well I found my right muffler baffle is loose and rattling like you would not believe. Totally annoying at idle and take off! I observed that the baffle is riveted in with 2 rivets. I sent the following
e-mail to Bub:

Hello,

            I have a set of your Boom Cans on my 2009 FLTRSE3 Harley. I have run them about 2 years with no issues. Today I started the bike and one of the baffles inside the muffler is rattling pretty bad. I think by now the packing has burned out and all that is holding the baffle is the rivet which is loose. I would like to know do you recommend repacking them or perhaps just drill out the rivet and install a new one? If either is the case can you provide packing and or a rivet? Not sure if the rivet needs to be stainless or some other special requirements so I am coming to you first. I am fully capable of drilling out the rivet and installing a new one. So please give me your recommendation? Other than this issue I love the mufflers and get lots of compliments! Thanks!


I received the following reply this afternoon:



Jeff,

Wow..I have not heard of this happening. Do you have a bike that vibrates a lot?

No worries, BUB Boom Cans are a very basic performance mufflers and easily repaired.

There is no packing- they have a specially designed baffles with two standard rivets: 3/16 x .50 grip sealed.

If you can't find them locally, let me know, I can throw a couple in an envelope for you.

Let us know if you need further assistance.

 

Warm regards,

Linnea


OK so I went and bought some rivets and when I got home got a light and took a look into the muffler. What I found is the baffle has 1/8 - 1/4" of movement. This make me think the hole is all wallered out and I don't think a new rivet will ever hold it in place for long. I guess I can add some washers and try it but did not really want to hillbilly up my bike! I was a Little taken back by the e-mail stating they have never heard of this problem and my bike must vibrate allot? Really this is the smoothest Harley I ever rode and I have ridden a dozen! So all you guys with Boom cans weight in and let me know if you have had or heard of this issue? I got a feeling these mufflers are headed for the barn!!!!! FACE

[mikegiotto]

Sucks to hear that. I just put these on and only have 200 miles on mine. I like the way they fill up the whole in the bag extensions, but I can tell they are not they highest quality.

[WestCoastRuss]

Face.....Checked the cans for rattles etc and all is tight after the two years I've had mine on.  Almost 2 years ago someone on here mentioned "performance" baffles that were (or use to be) available for the boom cans.  My memory isn't what it was years ago but I think the member who posted that was Wheelsnkeels???  Hope you get yours fixed-up soon......Russ

[grc]

If the holes for the rivets aren't snug, odds are you will have the same problem again.  You might want to try the next larger size (diameter) rivet and drill the holes out to the new size.  Odds are that the originals weren't tight when they were installed originally, and the small amout of movement has enlarged the holes over time.


Jerry

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If the holes for the rivets aren't snug, odds are you will have the same problem again.  You might want to try the next larger size (diameter) rivet and drill the holes out to the new size.  Odds are that the originals weren't tight when they were installed originally, and the small amout of movement has enlarged the holes over time.


Jerry

Yes that's what I think I am going to try. Probably pull it off tomorrow and get a better look once I drill out the old rivets. I have been hashing over a black exhaust systm for awhile now. This may be the push I need to jump into another system. Thx for the suggestions! FACE

[glens]

I gotta ask:  if you like the mufflers otherwise, and it seems you do by your first post, what's the big deal about having to swap out some rivets every couple of years?

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If I have to install larger rivets where does it stop? When I get 1/2" ones? I have also been down this road before with a set of super trapp mufflers. I took a ride from Sacramento to Phoenix and when I got home the holes were 1" long slots on an angle! Supertrapp replaced them and the next set weren't any better so I raised hell and they did me a deal on a 2-1 pipe.  If I am able to ride to Alaska next year I don't need any pending problems. I am going to fix these one way or the other but as far as replacing the system its just a need for some change, piece of mind and a sick addition to modifiying my motorcycles! I spent years replacing painted parts with chrome. Now that I have a chromed out bike I feel the need to go back to black. That and I'm too lazy to wash it every other week and I stress on a dirty bike (OCD). I know black gets dirty too!  FACE

[93-331-29psi]

Tap the baffle, and use a tapered allen or torx head bolt.  Worse case you have to tack a nut to the baffle.  I wouldn't worry too much, especially if you like them, it should be an easy fix.

[glens]

And use an adjustable wrench to slightly deform the baffle mounting ring(s) so it's more of an interference fit into the cans whereby the rivet/screw/bolt has less work to do.

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Ok, The holes were pretty big 7/32" to be exact. so off to the hardware store. I found 3/16" is the largest rivet they carry. Looked at a couple tools and they got up to 3/16" . So I found some steel grip tight 3/16' x 3/8" ones. I took a big pair of lineman pliers and worked the rim of the baffle pretty good all the way around. It was tight had to tap it in with the same pilers (even thought I probably had 25 hammers near by)  Next I used a punch to get the holes lined up good and put in the rivets. My cheap tool would not do it! I spent about 20 min going Thur my dads tools and finally found 2 heavy duty pairs in a drawer right in front of where I am working! Go figure? The Heavy duty tool was the trick but it still took two hands and some grunt! Well its in there and all back together! I fired it up and it sounds good. Checked left baffle and it is not loose "YEA" So now we will see how long it last. I believe it's probably better than new. I still feel a black exhaust coming on!