New Use for those Harley Mufflers

[Easter]

I am working on a CB900F and have been struggling to get it to run properly. Two obvious problems, pod style air filters and no baffles in the "mufflers". I tracked down an airbox on ebay and installed it but the exhaust system was going to be a major expense for a quality replacement.
Enter the ubiquitous Sportster mufflers___
installing them in place of the stock megaphones was not practical but in looking around for something to use for a baffle I decided that maybe the Sporty muffler could be cut down to fit inside the existing megaphone, crazy yes but it actually works. I had purchased three pair from a guy that owns or works for a local Harley dealer and so I still had a couple pair laying under the workbench. If I could make them work, $40 was a much better deal than $400 for a new system. A few minutes on the chop saw and now I had my baffles. I am not a welder so didn't attempt to weld all the way around but the fit is so tight that a hammer and block of wood were required to guide the baffle in place. A tack weld on the bottom where it is invisible will insure that the baffle stays in place. The bike now sounds loud but not objectionable and most importantly is running really well.

The second picture shows the cutaway of the Sportster muffler. It amazes me that exhaust can even get out. It is packed very tightly with fiberglass and has a couple hundred (I didn't count them) tiny, maybe 1/32 inch holes. No wonder the Harley crowd throws them away.

[CYBORG]

Looks good

[Whiskerfish]

yes it does!!

[BigSherm]

When I enlisted in the army in '87, I bought my first bike, an '82 CB900F.
It's always great to see one, and yours is great!

Scott

[Graham Cracker]

Nice work!

[luludog]

Very nice, looks like it was meant to be there.