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[Fullsac Performance]

Early CVO mufflers came from the factory with a sleeve of sound absorbing material that covered the inner wall creating an air gap between the core and the wall.
Some guys chose to remove this for a sharper more aggressive sound while others left it intact or even re wrapped it with thicker material in an attempt to quiet and soften
the exhaust note. Either way the power seemed to be for the most part unaffected. Come 2012, Harley made changes and starting stuffing the entire muffler with a sound absorbing blanket that consumed all of the space surrounding the core. People had similar choices, remove it all, none of it or part of it. My preference was to remove half and loosely wrap the inner core in an attempt to keep the wall covered like the earlier mufflers. On the dyno, I didn't notice anything dramatically different, but TQ numbers on the stage II builds seemed to be down a couple of points? The first 2013 CVO rolled in my shop at the end of last year and the customer requested the quietest Stage II build possible. I did my usual stuff but this time I stuffed all of the packing back in the muffler along with my 2.0 cores. The TQ numbers were embarrassing, 107 peak. I immediately removed all the packing and we jumped to 114 TQ. Eye opener for sure. The boring story ends here.

We now have perforated sleeves available for the 2012-13 CVO mufflers that work with the stock material. You simply cut one of the stock blankets in half, wrap the sleeve tightly and stuff it in. You now have enough material left over to rebuild them again at a later date. My previous recommendation of running half was the material was correct in theory, but in practice, the material was migrating to the end of the muffler and wadding into a ball. I have now installed and dynoed two 2013 CVO with the new sleeves in combo with the DX pipe and seen the highest TQ numbers to date from a stage I build at 118 FT pounds. Real lesson learned here is about muffler volume. Reducing it is bad. Keeping an air gap around the core is good.  

Below is the stock core and material coming out of a 2013 CVO muffler.

[Fullsac Performance]

New perforated sleeve with half of the original blanket ready to wrap.

[Fullsac Performance]

New perforated sleeve installed and ready for cores.

[2013SERG]

Steve, when will these be available?

[Poopy]

Would this work on 2011 FLHXSE2?

[tjablons]

Steve, when will these be available?
[/quote

When they be available, how much, and is a new TTS map needed with a C pipe and 2" baffles?

[Fullsac Performance]

The new perforated sleeves are available today. They will work in any CVO muffler or any 4" muffler. We do not supply the packing material.
If you have a 2012-13 CVO muffler, you already have enough material to do the job twice.Remapping is not required.

Contact me at steve@fullsac.com for pricing.

Thanks for your interest!

Steve

[bostonCVO]

Ok I am a little slow here. Do the new sleeves work in conjunction with the fullsac power cores? Or do the sleeves replace the stock cores and that is all that is needed?

[Fullsac Performance]

Ok I am a little slow here. Do the new sleeves work in conjunction with the fullsac power cores? Or do the sleeves replace the stock cores and that is all that is needed?

The sleeves work with the Power cores. All they are doing is holding the packing material in the proper place against the outer wall.

Steve

[110tHunDer]

 
Any chance of experiencing rattling of the sleeve against the core?

So, the power is better, but are you also saying this is more quiet than a fully-wrapped core?

[SBB]

"Damnit Steve!"
Your killing me.

 

SBB

[HDGearHead]

You're killing me smalls... (but in a good way) Ok, I've just replaced the C pipe with the DX pipe.  I also pulled the mufflers having the 2" CVO cores installed.

I purchased a second set of CVO mufflers taken off from a 2012 with less than 50 miles on them.  When I installed the 2.25" cores in them, I decided to install all of the packing to keep it on the quieter side.  The packing seems to be wrapped no tighter now than it was around the stock cores that came out.

I was about to take the bike back in for a re-tune but am now thinking that I may need to rethink this before going back to the tuner.  

How much space does the screen create between the core and packing?  How does the sound with the sleeve installed compare to a muffler having zero, half and all of the packing installed?  

Is there any chance of the sleeves rattling?  

Also do you have any tips on pulling the CVO cores back out of the muffler after they have been installed?  They fit very snug over the inlet end pipe (wire mesh seal between the core and inlet pipe) and there isn't anything to hook to pull them out (not like the stock core which could be knocked out using a wooden dowel).  When I put them in, I had to tap them in the last half inch using a rubber mallet.

[Fullsac Performance]

The first pic shows the stock core coming out with 100% of the space inside consumed by packing material.

The second pic shows the new perf screen sitting on top of half of the original material.

Pic three shows the sleeve installed, again with half of the original material. The sleeve has been compressed, wrapped tightly and very snugly slid in.
The perf sleeve is keeping the material to the wall very tightly. For this to rattle, all the packing material would have to burn away allowing contact to the muffler body.
That's alot of material to roast.

Core touching the screen? My biggest core 2.25, Looks like about a 3" hole. I Don't think we will have any issues. Been running a set in my bike for over 6 months.

Steve

[bostonCVO]

Steve, Could t he screen touch the ends of the cores causing a rattle? That would be my concern. I agree the packing material will keep the screens from contacting the inner walls of the mufflers. Like gains so these would be on my shopping list.

[Mr D]

The first pic shows the stock core coming out with 100% of the space inside consumed by packing material.

The second pic shows the new perf screen sitting on top of half of the original material.

Pic three shows the sleeve installed, again with half of the original material. The sleeve has been compressed, wrapped tightly and very snugly slid in.
The perf sleeve is keeping the material to the wall very tightly. For this to rattle, all the packing material would have to burn away allowing contact to the muffler body.
That's alot of material to roast.

Core touching the screen? My biggest core 2.25, Looks like about a 3" hole. I Don't think we will have any issues. Been running a set in my bike for over 6 months.

Steve

Steve,

The core then slips into the screen unwrapped?