ThunderHeader reverse cone replacement

[Hossamania]

The reverse cone "baffle" in my ThunderHeader has gone MIA (90,000 miles, 15 years). Is there some type of replacement I could slip in and bolt in place? Or do i buy a new pipe? Remember, cheap sob here.
Would a 1/4" bolt across the opening help at all, a-la drag pipe mod to break up reversion?

Before:
[attach=0,msg1361613]

After:
  [attach=1,msg1361613]

[kd]

  "One repair per year, thank you!"


Change your mind?   

[Leed]

I doubt you'll find one with such a unique shape... 

[Hossamania]

I doubt you'll find one with such a unique shape... 

I will say mine was a little messed up in that picture! It had rattled loose, I put some bends in it to stop the rattling, but eventually the last few points holding let go. It really did look like hell before it went flying!

  "One repair per year, thank you!"


Change your mind?   

It's on the list, no promises....

[Jaystn62]

15 years with the same pipe? I do good to make it a couple years with the same bike......

[crock]

Find you a washer that will fit to where you need it then tack weld it in place

[Hossamania]

Something like this looks interesting, not exactly what I'm looking for, but cheap enough to try.

http://www.nichecycle.com/ncs/categories/exhaust/baffles/80-84039-muffler-insert-xs-by-emgo.html

Find you a washer that will fit to where you need it then tack weld it in place

That might be worth a try. The next question, what size washer? Maybe make up a few different sizes and start testing!
Or, just buy a new TH. The wife will love that....
The reverse cone works well on the TH, I can feel a flat spot down low without it, and maybe some effect in the top end too, but that could just be my imagination.

[Trouble]

Tunable and cheap? Let us know how well it works and sounds compared to original TH.

[rigidthumper]

Cut a piece of 1/4" rod just long enough to fit snugly inside the pipe, just in front of/before the reverse cone. Tack weld a washer the same diameter as the opening of the front of the muffler, to the rod. Place the assembly inside the pipe, washer @ 90° to the flow, tack weld top and bottom & ride. Lo end should come back, sound should be very close to pre-baffle exit.

[Jaystn62]

Hoss I have a couple of those Thunder Thrust inserts that DK Customs sells laying around if you'd like to try one. Came out of mufflers on a Sporty I used to own. I'll probably never use them. Just let me know.

[Hossamania]

Hoss I have a couple of those Thunder Thrust inserts that DK Customs sells laying around if you'd like to try one. Came out of mufflers on a Sporty I used to own. I'll probably never use them. Just let me know.

Thanks for that offer, I will send a pm if I get to that point. Much appreciated!

[Hossamania]

Cut a piece of 1/4" rod just long enough to fit snugly inside the pipe, just in front of/before the reverse cone. Tack weld a washer the same diameter as the opening of the front of the muffler, to the rod. Place the assembly inside the pipe, washer @ 90° to the flow, tack weld top and bottom & ride. Lo end should come back, sound should be very close to pre-baffle exit.

I will give it a try. When you say place it in front of the baffle, are you talking at the beginning of the muffler, or at the exit? No way to get at the front of the muffler at the collector, welded one piece pipe.

[rigidthumper]

Washer size should be the same as the opening at the front ( engine) side of the baffle- if it's 1.75, then use a 1 3/4" diameter washer. If it's a 2 " opening, use a 2" OD washer.

[Hossamania]

When you say tack weld in front of the intersection of the reverse cone, are you talking at the collector, or at the tailpipe?

[Jaystn62]

Hoss I have a couple of those Thunder Thrust inserts that DK Customs sells laying around if you'd like to try one. Came out of mufflers on a Sporty I used to own. I'll probably never use them. Just let me know.

Thanks for that offer, I will send a pm if I get to that point. Much appreciated!

Anytime.

[Hossamania]

When you say tack weld in front of the intersection of the reverse cone, are you talking at the collector, or at the tailpipe?

I have figured out what you mean, I'm a little dense sometimes, mods to happen sometime soon hopefully.

[Hossamania]

What a out something like this, or would this be a horsepower killer?

https://www.jegs.com/i/Dynatech/329/772-32520/10002/-1?gclid=Cj0KCQjwnqH7BRDdARIsACTSAdsmxbBpVThdbui89TSKN7Coz6zJvc8x5BPtFoUk4kiGXX8c6HG8i7kaAhQDEALw_wcB

[Jaystn62]

I've seen these before but could never get any real reviews on them. Being perforated metal I can see where they could work.

[Hossamania]

I suppose I could drill bigger holes in it if it's too restrictive. I'm looking for a baffle shaped like the original reverse cone rather than just a washer and bolt. May end up with that anyway.
Or, like I say, I could buy a new pipe, but $60 and some time is more attractive than $900 or more.

[Jaystn62]

I suppose I could drill bigger holes in it if it's too restrictive. I'm looking for a baffle shaped like the original reverse cone rather than just a washer and bolt. May end up with that anyway.
Or, like I say, I could buy a new pipe, but $60 and some time is more attractive than $900 or more.

I agree with the $60 vs $900. Might be able to nibble away at the cone and fine tune it? Maybe?

[Barrett]

The Big City Thunder quiet baffles I had looked like that but with a lolipop also. I noticed more bottom end pull but didn't notice any top end loss.

[kd]

I suppose I could drill bigger holes in it if it's too restrictive. I'm looking for a baffle shaped like the original reverse cone rather than just a washer and bolt. May end up with that anyway.
Or, like I say, I could buy a new pipe, but $60 and some time is more attractive than $900 or more.

How's chances you could reproduce a reasonably similar shaped unit out of curled sheet metal.  You obviously must know what it looked like before you mashed it up to prevent it from spitting out (oops    )  You could probably make something close with a ball peen hammer, a piece of pipe in your vice as a form, and your favorite creative strain of herb.  A couple of nuts welded to the inside of the fixture to secure it in the pipe and Bob's yur uncle.   Just sayin   

[Hossamania]

That's probably not happening, I'll just keep looking for a baffle to bolt in and possibly modify.

[rigidthumper]

What a out something like this, or would this be a horsepower killer?

https://www.jegs.com/i/Dynatech/329/772-32520/10002/-1?gclid=Cj0KCQjwnqH7BRDdARIsACTSAdsmxbBpVThdbui89TSKN7Coz6zJvc8x5BPtFoUk4kiGXX8c6HG8i7kaAhQDEALw_wcB

I believe that would be effective.

[Hossamania]

Thanks Thumper, I may give it a try. Jay is sending some lollipops to me, I will try one of those first, then see where I go from there.
One of the challenging issues is that the ThunderHeader has the reverse cone welded on the end of the pipe, I need to reach inside past that, probably 8" or more, to attach the baffles/lollipops and hold the fastener. Creative solutions are being worked on in my head.