4th gen guys.. exhaust question

I messaged a few of you guys about this mod already. I'm going to do it this week or next and just wanted to know a few things. One, cut the 8 inches or so from the cap down, right? Did you cut anything out of the inside or just cut and recap? Best way to recap? Machine Screws, stainless steel bolts, rivet gun? Anything I need to look out for after the mod is done? Anything I may run into that's not talked about in this thread? I know its a lot of questions but I never done a mod like this and don't want to mess it up. Thanks

 

I'm one of those that you PM'ed. I figured it would be best to reply to the group. I didn't do a whole lot of planning. I just looked at the muffler and figured cutting 8" would give the look I wanted.

I removed the end cap first by drilling out the rivits and using a cold chisel to bend out the can so I could remove the end cap. It is held on by some sort of epoxy.

Then, I cut the can to the desired length. I pulled some of the batting, but just so I could slide in the end cap. I drilled 3 holes and used sheet metal screws to hold the end cap in.

Like the rest of my bike, it is a little rough up close but looks good at about 10 feet.

 

My 95 came with a V&H SS2-R slip on already on it. They use 4 screws to hold the end cap on so you can change baffles easy. The 1st time I opened it up it had nothing around the baffle no packing. It sounded ok but a little tinny. I cut 30% of the front of the baffle off sound a little better but I was not happy. I tried running without the baffle the tin noise just bugged me. took the tip off the end cap with no baffle and wow it sounded great but after a hour of riding I had to put it back on it was too loud. My last mod was to slide 2 1/8" pipe down to the front camber exit and slide the baffle into that pipe and put the end cap back on with no tip. So it has a small front camber and the 2nd chamber is pretty much a straight pipe. no cutting, drilling, or welding needed. I think it sounds great, it is loud but most HD's are louder. Looks almost stock it is not shortened at all. I will try to get some sound clips of it to post. And I can always put it back to semi quiet with a baffle. They still have some stock (unknown DB),102db, and 107db baffles for it around.

 

I don't like the looks of a shorty / stubby, I prefer my up high side mount, but the sound on one of those U tube links by the OP was sweet , sounded just like a 351 Cleveland flat tracker stock car with open headers.

 

I just did it last week. Takes about 30 minutes. Sound change is.....amazing. Off Idle throttle blips are RAW SEX.
4000 rpm is loud but at highway speeds it is fine.

My neighbors hate me now, but I am OK with that.

 

Well it turns out it was TOO LOUD. So I built a baffel out of a Samson A-148 Exhaust baffle.
The A-148 fits perfectly in the muffler end cap. Alone it is still loud. I had to block off the inlet of the A-148 with a 2 1/4" plug and wrapped it with muffler packing.

WOW what a difference. Now I have enough backpressure and limited to no pop on decelleration.