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.

[Jaystn62]

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.

Get you a set of those foot long needle nose pliers to get it in place and get the nut started. After that I bet you could get creative with a wrench.

[Hossamania]

That's actually my plan, I have one of those long needle nose pliers, I use it more often than I thought I might!

[Hossamania]

 

[76shuvlinoff]

 I was always tempted to cut open the T-Header on my shovel and maybe sneak a little packing in to tame it a bit. At that point I'd have to go from chrome to BBQ black or some high temp powder coating.  It's getting more ratty by the year so who knows?  Another 10 years I might be ready. 

[Hossamania]

All better! Thank you to Jaystn62, offered up his lollipops for free, much appreciated! What is it with this site that everyone helps everyone?
Only took it for a short ride until the rain started in, again, felt good down low, I will have to wait to do a top end run, run it thru it's paces.
[attach=0]
[attach=1]

[Jaystn62]

All better! Thank you to Jaystn62, offered up his lollipops for free, much appreciated! What is it with this site that everyone helps everyone?
Only took it for a short ride until the rain started in, again, felt good down low, I will have to wait to do a top end run, run it thru it's paces.
[attach=0,msg1363164]
[attach=1,msg1363164]

You put it in backwards! Hehehehe.....J/K. I have no idea. Looks good. Now you have to find someone to give the other one to. Like the family fruitcake. 

[Hossamania]

The other one will be a spare for when this one flies out!

[Jaystn62]

The other one will be a spare for when this one flies out!

Probably 15 yrs from now............

[Hossamania]

Let's hope it doesn't happen first ride!

[kd]

Well you won't have to drill a hole. 

[Hossamania]

Looking at the positive side like always, kd!

[Jaystn62]

Well if it falls out we know who installed it.

[Hossamania]

Yup, that's why I'm glad I have a spare ...

[Jaystn62]

Yup, that's why I'm glad I have a spare ...

Hehehehe.....good luck with it. Hope you never need a spare.

[Hossamania]

I was able to take it for a ride last night. It had better manners, smoother down low and when the throttle was cracked, the flat spot wasn't as bad, though this motor has always been soft down low, a product of its build and cam choice. (And a slight vacuum leak again, I suspect. Could even be a worn carb, 90,000 miles on it.)
The exhaust report was much less sharp to the ears, expected as it is not open pipe anymore. It sounded pretty good, though I am a fan of drag pipes and their ear shattering cackle, I think the people I passed didn't find it as obnoxious. It also seemed to smoothe out the idle and just off idle "lugging" in gear.
The top end seemed mostly there, maybe the quieter exhaust note seems to tone the rush of power, it still gets up and goes just fine. A test against friends' bikes will tell the tale.
I did not bring any wrenches with me to play with the angle of the lollipop, that will be next.
And it didn't come loose, so a win there!

[Jaystn62]

I'm glad it appears to be working for you. Just something that's been hanging around in my garage for years.

[Hossamania]

I turned the lollipop 90° to least restrictive position, the exhaust note is a bit sharper at speed and idling, but not like the open pipe. It ran surprisingly well, low and mid range response was good, the flat spot when cracking the throttle in 5th gear at 60 mph seemed no worse than with the previous position, it may even respond slightly better, I did not expect that. I did not get a chance to lug it just off idle in gear to check the sound and "chug".
Top end seemed better, so for now, it stays in this position.
Plus, who doesn't like a loud ThunderHeader?