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Welding mufflers on today, opinions before cutting please

Discussion in 'XJ Modifications' started by brianf408, Mar 19, 2010.

  1. brianf408

    brianf408 Member

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    Ok, so I put some sportster mufflers on the bike last year. I used a 1.5 to 1.75 inch pipe adapter, slipped it into the mufflers and slipped that onto the bike. I've ridden since then with nothing holding them on other than one bolt on the hanger and gravity holding them down on the pipes, so naturally they come loose on big bumps and leak a bit of exhaust. Here's a pic:

    [​IMG]

    The clean steel is the adapter, then the blued piping is the start of the muffler. Now my 2 options are:

    1. Just weld the adapters on how they sit, and leave it pretty much as it is.

    2. Chop the blued piping off where it's factory welded to the Harley muffler and weld the muffler directly onto the exhaust. This would shorten about 6 inches, which would put them at the same length as the stock pipes (right now I think they're too long and stick out too far to the sides.)

    Any thoughts? I'll be using the oxy/acetelyne torch here at work. I'm just afraid of chopping the mufflers and having it suck to weld up, then having to get new mufflers.
     
    brianf408, Mar 19, 2010
    #1
  2. streetbrawler750

    streetbrawler750 Member

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    I would put a half or three quarter inch long weld on the bottom and back side of the pipe and the adapter instead of welding solid, it would hide it and do the trick of keeping together.
     
    streetbrawler750, Mar 19, 2010
    #2
  3. albran

    albran Member

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    Re: Welding mufflers on today, opinions before cutting pleas

    I painted the muffler adapter and muffler clamp with high heat paint.
    I had 1 chrome clamp.

    Try cutting the sportster pipe short enough to just fit in the adapter, looks like you could make it several inches shorter.

    albran
     

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    albran, Mar 19, 2010
    #3
  4. PainterD

    PainterD Active Member

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    Re: Welding mufflers on today, opinions before cutting pleas

    Brian,
    You need to use a short bracket (homemade) out of some flat stock (aluminum worked for me) to attach the mufflers to the bottom of the rear footpeg mounts. Those mufflers are too heavy to have them just hanging off the collector/header pipes. Just a suggestion. Ride on!!
     
    PainterD, Mar 21, 2010
    #4
  5. brianf408

    brianf408 Member

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    Re: Welding mufflers on today, opinions before cutting pleas

    They're hanging on the stock brackets. The mufflers each have 2 knobs that are threaded, and in the perfect place to hang from the stock bracket. Just found a bolt that fit the threads and ran it thru the bracket. I'll try to get some pics up, since I've never seen ones like it on here.
     
    brianf408, Mar 21, 2010
    #5
  6. spinalator

    spinalator Member

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    Re: Welding mufflers on today, opinions before cutting pleas

    I will do this soon as well, good ideas!
     
    spinalator, May 7, 2013
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