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Old 07-20-2018, 09:42 PM   #1
Tumminelli
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Join Date: Apr 2018
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Default Muffler surgery

When I shook my muffler there was a lot of rattling going on. These early big mufflers don't seem to be available any more from what I found. So I had to do surgery.
I wasn't sure where to start cutting so I decided to cut at the long seem across the bottom. Then I drilled out the spot welds on the edges. Little did I know that was only a cover over the muffler. There was a heat retarding material sandwiched between it and the muffler. I think it may be asbestos. I went for my mask a that point.
After removing the cover I made a big rectanular cut to expose the inside of the muffler. One baffle was totally off the other was real loose. I put the pieces bake together and Tack welded them in position.
Putting the case back to be the was a little harder. I think these things are pressed together by machines. I had to use some ratchet straps to pull it together but I still had to add a cheat strip to get it back together. I've uploaded some photos. Hope this helps somebody else with a bad salvageable muffler.
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Old 07-20-2018, 09:45 PM   #2
Tumminelli
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Default Re: Muffler surgery

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Old 07-20-2018, 09:51 PM   #3
Tumminelli
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Default Re: Muffler surgery

Last photos
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Old 07-20-2018, 10:12 PM   #4
AKAMick
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Default Re: Muffler surgery

Nice job!, my later style muffler 77 was similar just minus that heat shielding when i repaired mine,
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Old 07-21-2018, 05:54 AM   #5
raydhd
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Default Re: Muffler surgery

With seeing what is inside these mufflers I wonder if you took a fairly large sized modern turbo type muffler and reduced the size of the outlet if it would not work ?
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Old 07-21-2018, 07:23 AM   #6
TheNewGuy
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Default Re: Muffler surgery

Good job!!

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Old 07-21-2018, 12:52 PM   #7
Tumminelli
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Default Re: Muffler surgery

Yes I think that will be my next move. Good idea!
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Old 11-20-2020, 03:51 PM   #8
raydhd
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Default Re: Muffler surgery

I see the days of the $125 harley muffler are no longer. Too Bad
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