Bolting on HD Mufflers

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tomk1960
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Bolting on HD Mufflers

#1

Post by tomk1960 »

I have a set of Harley take-off mufflers that I intend to use on my '78 GL project. I'll be ready to bolt them on in September and want to know what I need in order to do this. At the very least, I'll need to fabricate some short brackets for them to be properly supported. Some clamps where they slip onto the headers will be needed as well. What else do I need to know or can someone point me to a thread that gets into this in detail. Some pics would be great.

Thanks.
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leggman
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Re: Bolting on HD Mufflers

#2

Post by leggman »

I had to weld some muffler pipe to the headers because the harley mufflers were just a little too big, then made brackets. I will post pics after school today.
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Pony Ruiz
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Re: Bolting on HD Mufflers

#3

Post by Pony Ruiz »

I did this on a 78 as well. Harley dyna mufflers. The pipes were trashed so I ended up with 1100 headers that I had to get a muffler pipe welded on. Bought some muffler clamps from Harley that fit. Put the mufflers on the headers then proceeded to make the supporting brackets out of wood / 1/4" plywood. Once I had the pcs. I cut them out of metal and had a good forum buddy weld them up. I set it up to keep the center stand and use the existing brackets for a base. I still have the patterns if you want to use them.
https://drive.google.com/file/d/1dGqeG- ... sp=sharing

I'm almost done with this thing. It starts runs rides. Needs some tweaking and a redo on the clear coat.
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tomk1960
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Re: Bolting on HD Mufflers

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Post by tomk1960 »

Pony Ruiz wrote:I did this on a 78 as well. Harley dyna mufflers. The pipes were trashed so I ended up with 1100 headers that I had to get a muffler pipe welded on. Bought some muffler clamps from Harley that fit. Put the mufflers on the headers then proceeded to make the supporting brackets out of wood / 1/4" plywood. Once I had the pcs. I cut them out of metal and had a good forum buddy weld them up. I set it up to keep the center stand and use the existing brackets for a base. I still have the patterns if you want to use them.
https://drive.google.com/file/d/1dGqeG- ... sp=sharing

I'm almost done with this thing. It starts runs rides. Needs some tweaking and a redo on the clear coat.
This is great - I'll check them out tonight to see what's involved. I definitely want to save the center stand. I'll look at what you did as well as consider the center stand stoppers that SuperTrapp used to provide with their 4-into-1 exhausts. I can always make something like those that will be out of sight.

Thanks!
1986 VFR750F Interceptor
1983 Honda CB1100F Super Sport - Red 1123 Resto-Mod
1978 Honda GL1000
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desertrefugee
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Re: Bolting on HD Mufflers

#5

Post by desertrefugee »

I bolted Sportster mufflers to my 78 with no hassle at all. Harley clamps and a couple of brackets a d that was it. I did use some Kevlar tape as a gasket as the factory ring was too thick. Angle and length are perfect for me with no additional piping or extension.
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Re: Bolting on HD Mufflers

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Post by SnoBrdr »

desertrefugee wrote:I bolted Sportster mufflers to my 78 with no hassle at all. Harley clamps and a couple of brackets a d that was it. I did use some Kevlar tape as a gasket as the factory ring was too thick. Angle and length are perfect for me with no additional piping or extension.
I did the same but used a chrome sleeve from Auto Zone which I attached to a bracket that attaches to the passenger pegs.
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robin1731
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Re: Bolting on HD Mufflers

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Post by robin1731 »

The only picture I have of my carb dyno with sportster mufflers. Some short pipe added at the header to mate them up. Then the stock muffler hanger bolted to the stock rear passenger pegs.

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Re: Bolting on HD Mufflers

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Post by leggman »

Here is what I did. There is a video in my build thread in 77 barn find
20180814_155601.jpg
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20180814_155631.jpg
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tomk1960
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Re: Bolting on HD Mufflers

#9

Post by tomk1960 »

That bracket picture is very helpful and it looks like the Harley mufflers I have are a pretty decent fit to the header:

Image

Some Kevlar tape and a couple of nice clamps should do the trick, provided that the muffler lands in the right spot for a support bracket. If necessary, I can always add a couple of exhaust extensions for better alignment.
1986 VFR750F Interceptor
1983 Honda CB1100F Super Sport - Red 1123 Resto-Mod
1978 Honda GL1000
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Re: Bolting on HD Mufflers

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Post by SnoBrdr »

leggman wrote:Here is what I did. There is a video in my build thread in 77 barn find20180814_155601.jpg20180814_155631.jpg
Looks real nice.

Couldn't do that with mine as the mounting holes on the muffler are almost at the end of the cone itself.
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