Differences

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--- techtalk:ref:carb04 [2018/11/04 20:19]
hippysmack [The Gronk Exhaust Mod]
+++ techtalk:ref:carb04 [2024/01/11 01:43]
hippysmack
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== REF: Carburetor, Intake Manifold & Exhaust ======
+====== Exhaust Leaks ======
+You can put your hand near the pipes at likely places for leaks (exhaust ports, any joints) and see if you can feel air escaping. ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/118650-exhaust-port-gaskets-installation-tricks?highlight=stethoscope#post3727356)) \\
+But, be careful not to burn yourself on the pipes.
+===== Smoke Test =====
+When oil is added to the combustion chamber, the result is smoke coming out of the exhaust. \\
+The oil burns and comes out as smoke. ((Folkie of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/118650-exhaust-port-gaskets-installation-tricks?highlight=stethoscope#post3727356)) \\
+The smoke should just come out the ends of the mufflers. \\
+If smoke is coming out anywhere else, that's where your leak is. \\
+Test one cylinder at a time. \\
+  - Pull a spark plug.
+  - Add a spoonful of standard motor oil in the cylinder.
+  - Reinstall the plug.
+  - Fire up the engine.
+  - When it starts to smoke put a rag in the exhaust pipe and look for leaks.  It helps if you have a buddy hold the rag
@@ Line 8: / Line 25: @@
 ===== Drilling a Hole in the Baffle =====
 A lot of people drill the baffle plug out of the standard mufflers. \\
-But it can create tuning issues due to "wave reversion". problems. ((gronk62 of the XLFORUM http://xlforum.net/forums/showthread.php?t=16948)) \\
+But, use at your own risk. \\
-Use at your own risk. \\
+__Issues with doing this mod include__; \\
+**Tuning**: \\
+It can create tuning issues due to "wave reversion". problems. ((gronk62 of the XLFORUM http://xlforum.net/forums/showthread.php?t=16948)) \\
-This was done with a 3/4" hole saw on a 10" drill extension. \\
+**Unwanted noise**: \\
+Some say it will make a chirping sound if you drill the whole baffle plug out. \\
+Others say it will only make the whistling / chirping sound if you take the whole 1-1/4" inch baffle plug out. ((Don Burton http://xlforum.net/forums/showthread.php?t=1392884&page=2)) \\
+And a 3/4" hole through it won't make that sound. ((AsSeenOnTV http://xlforum.net/forums/showthread.php?t=1392884)) \\
+**Overall sound**: \\
+Reportedly, the bike should sound better than the stock. \\
+This mod adds volume, and more low end 'sound' than the stock version. ((AsSeenOnTV http://xlforum.net/forums/showthread.php?t=1392884))
+**Failed inspections**: \\
+Once the muffler baffles are drilled, it can easily be detected that you have 'tampered' with them. \\
+Depending on where you live, your bike may not pass inspection due to this mod. ((AsSeenOnTV http://xlforum.net/forums/showthread.php?t=1392884)) \\
+This was done with a 3/4" hole saw on a 10" drill extension. ((AsSeenOnTV http://xlforum.net/forums/showthread.php?t=1392884)) \\
 |If exhaust is installed, make sure the set screw in the extension is tight so you don't drop the hole saw inside it. ((photos by bboerst31 of the XLFORUM http://xlforum.net/forums/showthread.php?t=792768))  ||
 |{{:techtalk:ref:tools:hole_saw_and_drill_extension_1_by_bboerst31.jpg?direct&300|}}|{{:techtalk:ref:tools:hole_saw_and_drill_extension_2_by_bboerst31.jpg?direct&300|}}|
-|Drill out the center of the baffle. ((photos by bboerst31 of the XLFORUM http://xlforum.net/forums/showthread.php?t=792768))|||
+|Drill out the center of the baffle (3/4" hole saw used here). ((photos by bboerst31 of the XLFORUM http://xlforum.net/forums/showthread.php?t=792768))|||
 |{{:techtalk:ref:carb:drilling_exhaust_baffle_1_by_bboerst31.jpg?direct&300|}}|{{:techtalk:ref:carb:drilling_exhaust_baffle_2_by_bboerst31.jpg?direct&300|}}|{{:techtalk:ref:carb:drilling_exhaust_baffle_3_by_bboerst31.jpg?direct&300|}}|
+Other variations: \\
+|Holes drilled around the baffle ((photo by Bob F of the XLFORUM http://xlforum.net/forums/showthread.php?t=1392884))|
+|{{:techtalk:ref:carb:drilled_mufflers_by_bob_f.jpg?direct&300|}}|
 ===== Modifying standard mufflers for better flow and sound =====
 ==== The Gronk Muffler Mod ====
 Article by gronk62 of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=16948)) \\
-This mod is for when you don't like having loud pipes or the 'chuff chuff' sound the standard mufflers make.
+This mod is for when you don't like having loud pipes or the 'chuff chuff' sound the standard mufflers make. \\
+The mod gives a great sound with zero metallic blat! ((Don Burton http://xlforum.net/forums/showthread.php?t=16948&page=3)) \\
-A lot of people drill the baffle plug out of the standard mufflers but I have read this can create tuning issues due to "wave reversion" problems (dunno what that is though. Crim, Shu and Stevo know heaps about this stuff)
+OEM mufflers are quite restrictive so the baffles were removed with a 1-3/4" hole saw and the holes were drilled bigger. \\
+(enlarged to 1/4" or 6mm and also added a couple of extra rows on the outlet side of the baffle plug). \\
- OE mufflers are also quite restrictive so I removed the baffles with a 44mm (1 3/4") hole saw and enlarged the holes in them to 6mm (1/4") and also added a cuppla extra rows on the outlet side of the baffle plug.
+The baffle plug must be left intact for the guide to sit on.
- The baffle plug must be left intact.
+Doing this mod helps to increase the gas flow and allow a more fuller and deeper sound without being too loud. \\
+But, it is unlikely to give much in the way of performance increase. \\
+Although your bike may feel slightly stronger at low to midrange revs. \\
- Doin' this helps to increase the gas flow and allow a more fuller and deeper sound without bein' too loud but is unlikely to give much in the way of performance increase. Although my bike feels slightly stronger at low to midrange revs which is where I spend most of my time riding anyway.
+You'll need flare the ends or have a muffler shop do them for you so it fits snug back in the the hole made by the hole saw. \\
+Then weld them in taking care not to blue the chrome. \\
+It helps to wrap a wet towel around the area to be welded to keep the chrome cooler. \\
+|You'll need to make a guide for the hole saw. \\ The guide slides down and stops at the baffle center piece. \\ The hole in the guide is for the pilot drill in the hole saw.||
+|Hole saw and home made guide. ((photo by gronk62 of the XLFORUM http://xlforum.net/forums/showthread.php?t=16948))|Guide installed, ready for the hole saw. ((photo by flak monkey of the XLFORUM http://xlforum.net/forums/showthread.php?t=1172778))|
+|{{:techtalk:ref:carb:gronk_mod_1_by_gronk62.jpg?direct&300|}}|{{:techtalk:ref:carb:make_your_own_baffles_1_by_flak_monkey.jpg?direct&300|}}|
+|The top baffle is standard. ((photo by gronk62 of the XLFORUM http://xlforum.net/forums/showthread.php?t=16948))|Note when welding them back in,\\ They don't have to be welded the whole way round. \\ A couple short welds will do. ((photo by gronk62 of the XLFORUM http://xlforum.net/forums/showthread.php?t=16948))|
+|{{:techtalk:ref:carb:gronk_mod_2_by_gronk62.jpg?direct&300|}}|{{:techtalk:ref:carb:gronk_mod_3_by_gronk62.jpg?direct&300|}}|
- I then have the outlet end flared (I had to have flares made that welded on the end of the baffle tube) so it fits snug back in the the hole made by the hole saw.
- Then weld them in taking care not to blue the chrome.
-It helps to wrap a wet towel around the area to be welded to keep the chrome cooler.
- This was done for me by the local exhaust shop.
-|{{:techtalk:ref:carb:gronk_mod_1_by_gronk62.jpg?direct&300|}}|
-|{{:techtalk:ref:carb:gronk_mod_2_by_gronk62.jpg?direct&300|}}|
-|{{:techtalk:ref:carb:gronk_mod_3_by_gronk62.jpg?direct&300|}}|
@@ Line 54: / Line 97: @@
 ===== Making Your Own Baffles =====
-Article by chickenhawk of the XLFORUM ((http://xlforum.net/forums/showthread.php?p=4990236)) \\
+Based on an article by chickenhawk of the XLFORUM ((http://xlforum.net/forums/showthread.php?p=4990236)) \\
 This is an easy and cheap way to create some decent Cycle Shack & Screaming Eagle type baffles for a cost of around $7 per baffle. \\
@@ Line 60: / Line 103: @@
 If your slip-ons are missing the baffles, you can gain some midrange back and get a nice deep sound by adding baffles. \\
-These below adjustable so this is a good starting point. \\
+The ones below are adjustable so this is a good starting point. \\
 Modifications / Fine Tuning: \\
@@ Line 118: / Line 161: @@
 Drill more as needed after testing if you like. \\
-Sound varies between bikes. \\
+|Standard baffle ((photo by flak monkey of the XLFORUM http://xlforum.net/forums/showthread.php?t=1172778))|Holes in the baffle partially drilled out. ((photo by flak monkey of the XLFORUM http://xlforum.net/forums/showthread.php?t=1172778))|
+|{{:techtalk:ref:carb:make_your_own_baffles_3_by_flak_monkey.jpg?direct&300|}}|{{:techtalk:ref:carb:make_your_own_baffles_4_by_flak_monkey.jpg?direct&300|}}|
+Sound varies between bikes also. \\
 **Note**: if your baffles have a 1/4" space between the outside of the baffle and the inside of the slip-on, \\
@@ Line 152: / Line 198: @@
 They give some bottom and mid range back as well as help to smooth out the sound. ((thesavageone33 of the XLFORUM http://xlforum.net/forums/showthread.php?p=4990236)) \\
+|{{:techtalk:ref:carb:torque_cones_by_biknut.jpg?direct&300|}}|
+|  Torque Cones ((photo by biknut of the XLFORUM http://xlforum.net/forums/showthread.php?t=643292))  |
 ====== Lollipops ======
+{{ :techtalk:ref:carb:lollipop_drawing_by_shotgun46.jpg?direct&200|}} ((drawing by shotgun46 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1552356&page=2)) \\
   *  A "Lollipop" is a cheap simple way of achieving back pressure on the pipes and creating anti-reversion.
@@ Line 164: / Line 211: @@
+|  Thunder Monsters (fancy lollipops) ((photo by biknut of the XLFORUM http://xlforum.net/forums/showthread.php?t=643292))  |
+|{{:techtalk:ref:carb:thunder_monsters_by_biknut.jpg?direct&300|}}|
@@ Line 247: / Line 295: @@
 |Washer welded to 1/4" bolt w/ bolt inserted into washer((photo by rooster77 of the XLFORUM))|Eyebolt ((photo by xllent01 of the XLFORUM))||
+====== Patriot Defender ======
+Dims: ((rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?p=5737508)) \\
+-3/4" diameter out of the heads. \\
+Out to 2". \\
+Then 2-1/4" to the collector. \\
+The collector is probably 2-1/2" in a megaphone configuration. \\
+|  Patriot Defender Pipes Pics and Dims. ((photos by rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?p=5737508))  |||
+|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_1_by_rocketmangb.jpg?direct&300|}}|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_2_by_rocketmangb.jpg?direct&300|}}|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_3_by_rocketmangb.jpg?direct&300|}}|
+|  Patriot Defender Pipes Pics and Dims. ((photos by rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?p=5737508))  |||
+|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_4_by_rocketmangb.jpg?direct&300|}}|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_5_by_rocketmangb.jpg?direct&300|}}|{{:techtalk:ref:carb:patriot_defender_pics_and_dims_6_by_rocketmangb.jpg?direct&300|}}|
 [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]]
+====== Exhaust Bracket Mods ======
+Exhaust brackets can be fabricated to fit just about any configuration needed. \\
+(especially when using aftermarket pipes) \\
+Mount the pipes to the heads with proper torque. \\ Allow them to **gently** sit on their own. \\
+This allows for vertical and horizontal measurements to be taken from the point where the mount mates to the pipes. \\
+Below is the bracket that comes with the purchase of a set of Thunderheaders. \\
+This particular bracket was slightly too low and recessed to fit on a 98 1250. \\
+(it may have been fine for stock 1200 heads) \\
+The plate on the bracket was cut into and another plate was welded to it to extend the mounting holes. \\
+With the extra plate simply welded on top of the original one, the height worked out as well. \\
+|  Thunderheader bracket mod. ((photos by Hippysmack))  |||
+|{{:techtalk:ref:carb:thunderheader_bracket_mod_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:carb:thunderheader_bracket_mod_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:carb:thunderheader_bracket_mod_1_by_hippysmack.jpg?direct&300|}}|
+|{{:techtalk:ref:carb:thunderheader_bracket_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:carb:thunderheader_bracket_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:carb:thunderheader_bracket_7_by_hippysmack.jpg?direct&300|}}|
 \\

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