Adapting Harley Mufflers


Information and questions on GL1100 Goldwings (1980-1983)
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MJSantos
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Adapting Harley Mufflers

Postby MJSantos » Wed Jan 19, 2011 6:38 pm



This is what I have so far. The original GL1100 mufflers were shot, BIG RUST HOLES, I cut the manifolds away just before the welds. In the pictue you can see the harley Muffler positioned where the clamp point is just after the center stand. The stand is in the facory up position. The template in place shows what the connecting pipe would look like. Today a friend of mine saya that with that much angle it would make a popping sound verses a melow tone. Has anybody done this and would smoothing the curve to more like 30 degrees work better? The second photo shows how far the mufflers extend out the back which is even with the rear bumper. The other two pics show there they are under the bags and the last gives and idea of how much header material I can play with. Blue tape shos the cutoff point.
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littlebeaver
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Re: Adapting Harley Mufflers

Postby littlebeaver » Wed Jan 19, 2011 7:32 pm

Cool stuff, try it, like it is..Nice engine there.. :D

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Re: Adapting Harley Mufflers

Postby detdrbuzzard » Thu Jan 20, 2011 6:58 am

in pic #2 the left muffler seems to extend farther back than the right muffler. my niece has to do something about her exhaust. she already has the rk mufflers
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Re: Adapting Harley Mufflers

Postby MJSantos » Thu Jan 20, 2011 8:36 am

detdrbuzzard wrote:in pic #2 the left muffler seems to extend farther back than the right muffler. my niece has to do something about her exhaust. she already has the rk mufflers

The picture was taken a little off center. When I get ready for the final fit I'm going to take measurements to be sure. Thre's wiggle room for and aft for the placement I just don't want them to far out that would look hokey.

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Re: Adapting Harley Mufflers

Postby HALBUDD » Thu Jan 20, 2011 4:47 pm

Hey MJsantos After seeing some of your rebuilds, I have a question have you ever though about starting your own shop? I think if you started one just for older wings you would be up to your ears with work. I know even just cleaning eng. like in your pics would be great. Let us know if you ever get something like that going and keep up the pics love to see them. Hal
A woman that can use tools is worth her weight in gold !!

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Re: Adapting Harley Mufflers

Postby MJSantos » Thu Jan 20, 2011 5:33 pm

Opening a shop is risky. First it takes the fun out of working on the bikes since your under the gun to get them done. Then you have customers that no matter how much you do they're not happy. Working on these 30 year old machines is always a gamble. You never know what you're going to find. I was very fortunate with my first one that it was my uncle's and he's anal with his stuff. This one here was suppose to be a parts bike but the wife and I decided let's give it a shot. If it takes us a year to get it done then so be it, why rush it. Someone wanting to have their's done wouldn't see it that way and the cost would be more than what the bike would be worth. I guess polishing parts, rebuilding carbs and maybe brake componets wouldn't be that bad but again most folks would rather do it themselves. Maybe later I'll entertain doing that stuff during the winter downtime. Folks pull the parts send them and I'll return them. Just to give you an idea it takes me about four evenings just to do valve covers. Carb intakes another two days then the carbs themselves. This set was so bad it took two weeks just soaking and cleaning. Check out the photos in my gallery and you get an idea ust how bad.

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Re: Adapting Harley Mufflers

Postby littlebeaver » Thu Jan 20, 2011 10:49 pm

Hey Santo's did you repaint the engine and buff out everything else, sure looks good..Can't wait until your done..I wanna see..

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Re: Adapting Harley Mufflers

Postby MJSantos » Fri Jan 21, 2011 2:23 pm

Yes the engine was repainted and did the buffing. Once I get the exhaust welded up. Then I'll break down the frame again and do the final color painting and start on the tins. Everything else has been cleaned and ready for rebuild kits. All new brakes, wheel bearings rims to be painted. Seat has been done already. Still have the rest of the chrome to clean. With any kind of luck we should have her bike done sometime in April. Here's another shot of the engine and frame. Frame color is going to change. I had just painted it when the wife decided her color scheme, so it gets redone.
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Re: Adapting Harley Mufflers

Postby littlebeaver » Fri Jan 21, 2011 2:42 pm

You are using can paint right? My question is on the engine after your spray it's final coat do you or should you clear over it? I would bet your going to repaint all the brake calipers and small parts too? Maybe the inner rims too if scratches are there..May as well if you have come this far..I sure would..That's gonna be the cleanest bike around..If I were doing it for my wife I would go the extra yard..For sure..Good luck..It's killing me right now because there's a 83, 1100 for 900 bone's on criagslist and I want it, for a naked custom build..Man.. it's got everything.. :shock:

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Re: Adapting Harley Mufflers

Postby MJSantos » Fri Jan 21, 2011 3:10 pm

The engine paint is from the parts store the Duplicolor high temp engine stuff. Can't see putting clear coat over it. It has to be heated to cure. Yes the brake calipers have been broken down and cleaned along with both master cylinders. Everything will be repainted and new kits installed. The brakelines are going to be the stainless type so the only original lines will be the hard lines in the frame which have been cleaned out any waiting to be reinstalled in the frame. The wiring harness is going to have all of the connectors cleaned then it will be modified. I have to change the front end to accomadate the new headlight bucket and blinkers. No fairing on this bike so some of the connections that were in the weight on the original will have to be located back under the false tank. When I do the harness I'm adding the wiring for the running lights then rewrapping the harness so it will be fresh and new. She wants to put on something like a Memphis Shade but keep the front cleaned. Here's a picture of the light bar I made for it that will have runnning lights and blinkers. She wants the 7 inch headlight but it has to be the one for an H4 bulb. We are going over the a Harley Salvage yard tomorrow to look at lights plus I want to get the clamps for the mufflers. All of the hoses will have the braided covering on them along with the plug wires. With her vision of it I think it's going to be impressive and definetly a girls ride.
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Re: Adapting Harley Mufflers

Postby WingAdmin » Fri Jan 21, 2011 4:37 pm

Are you going to just try to refurbish the existing wiring harness? If there is one thing I'd love to do to my bike, it's rip out that harness and put a new one in, with fresh, new connectors, larger gauge wire, etc.

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Re: Adapting Harley Mufflers

Postby MJSantos » Fri Jan 21, 2011 4:57 pm

Actually from what I've seen of it the connector bodies and contacts looked pretty good. No real corrision or burns. The only spot that has a problem is where are harness passes down the left side of the frame. It was pinched at one time apparently by the seat so one of the wires is exposed. I'm going to open the electrical tape wrap about six inches either way amd see how bad it is. Porbably do a Western Union Splice putting in a new section. The wiring for the running lights that we had talked about before will be put inside the wrap. Like we had said I need to get to the Running light circuit for the taillight bulb but I don't want to have this new wire just running along Willy Nilley. I'm still planning on putting in a relay for the lights and a larger gauge power lead for them. Just in case at a later date we want to upgrade or change from LED to 55w running lights. The bulbs will be all LED with a new solid state blinker relay so that plug will be changed. I'll also add a plug male/female for the new front blinkers and another for the running lights. The stategy for those is if later I need to do fork seal I can unplug the lights in the front take four bolts off and the ligh bar and headlamp will come off then the forks will be free to pull off the bike. I'm also going to incorporate and headlight modulator which will be under the false tank and the brake light moduator but there is room for it in the rear unless she decides on a custom seat, Then I'll have to move it forward so it might just go under the tank too. I'm really kicking around the idea of welding another mount plate to the light bar and using a bottom mount head light. There seems to be more of them available and then it would be a two bolt operation. As you can see from the photo of the light bar mockup the two mount bolts are on the lower tree and were originally used for the cover used with the fairing and was where the HONDA emblem was mounted on the standards.

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Re: Adapting Harley Mufflers

Postby littlebeaver » Fri Jan 21, 2011 5:16 pm

I'm totally impressed.. :D

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Re: Adapting Harley Mufflers

Postby imfree » Sat Jan 22, 2011 6:52 am

What kind of harley did those mufflers come off ? If it was not a true duel system then you should look inside of them ,you might find that the left has hardley any baffle and the right is choked down.which I think will cause more back presure on the right side than the left.I might be wrong,But I don't think so.Maybe some experts out there can tell us .Joe

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Re: Adapting Harley Mufflers

Postby MJSantos » Sat Jan 22, 2011 8:22 am

imfree wrote:What kind of harley did those mufflers come off ? If it was not a true duel system then you should look inside of them ,you might find that the left has hardley any baffle and the right is choked down.which I think will cause more back presure on the right side than the left.I might be wrong,But I don't think so. Maybe some experts out there can tell us .Joe

Not quite sure of the naming convention used on Harleys but my friends looks like a Road King. These mufflers were the originals that the baffles have been punched out so you can see straight through. Don't think back pressure will be an issue. If they turn out to be too loud then we'll head over to the Harley shop here in York. They have a basement full of takeoffs. Once I have the pipes built and the mounts for them set up changing them out will be an easy thing.

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Re: Adapting Harley Mufflers

Postby WingAdmin » Sat Jan 22, 2011 11:34 am

You can stuff some stainless steel dish scrubbing pads in there (from the engine side, so they won't get blown out), and they will work very well as sound baffles. The same trick is used on old OEM Honda pipes where the baffles have rusted out.


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Re: Adapting Harley Mufflers

Postby imfree » Sat Jan 22, 2011 1:46 pm

Would it cause any damage to run straight pipes with no crossover pipe?

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Re: Adapting Harley Mufflers

Postby MJSantos » Sat Jan 22, 2011 2:22 pm

We'll see when I get it running if the steelwool trick will be needed. We just got back from the salvage warehouse and the wife spotted a turn down version. They only had the one but if these don't fit the bill then we'll run over to the Harley dealership and pick up a set of turndowns. The 1100s are pretty forgiving and from what I've read so far there won't be any adverse problems not having the crossover. If it comes down to it I can always put one on it.

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Re: Adapting Harley Mufflers

Postby MJSantos » Fri Jan 28, 2011 7:10 pm

Just a quick update just finsihed getting one muffler mounted and the brackets made. Hope to work the other side tomorrow. Found a muffler shop here in York that does cutom work for hotrods. Took my template in and this fellow in his 70s was impressive. Cutoff a section of 1 3/4 pipe eyeballed the bends and was done in minutes. Unreal but him and I talked for the longest time and he's been doin it since he was a teenager. It's getting to be a lost art.
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Re: Adapting Harley Mufflers

Postby thrasherg » Sat Jan 29, 2011 11:10 am

MJSantos wrote:Just a quick update just finsihed getting one muffler mounted and the brackets made. Hope to work the other side tomorrow. Found a muffler shop here in York that does cutom work for hotrods. Took my template in and this fellow in his 70s was impressive. Cutoff a section of 1 3/4 pipe eyeballed the bends and was done in minutes. Unreal but him and I talked for the longest time and he's been doin it since he was a teenager. It's getting to be a lost art.


That's the big problem these days, we have become a throw away society and are loosing all the people with the old skils required to make and repair things.. It's a real shame but I don't see it changing..

Congrats on getting the pipe fitted, it looks good..

Gary

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Re: Adapting Harley Mufflers

Postby MSGT-R » Sun Jan 30, 2011 11:35 am

Keep the pictures coming! It's looking really good.
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Re: Adapting Harley Mufflers

Postby littlebeaver » Sun Jan 30, 2011 11:40 am

Yes, I'm enjoying your progress too, but don't go rush anything because of us, maybe a youtube video with the sound cranked up :lol: I wanta hear it..I'm sure we are months from anything like that..

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Re: Adapting Harley Mufflers

Postby MSGT-R » Sun Jan 30, 2011 11:45 am

I like the idea of the scouring pad too!
Don't spook the road sheep.

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Re: Adapting Harley Mufflers

Postby MJSantos » Sun Jan 30, 2011 5:03 pm

Well it was a product weekend. Finished the muffler work and then broke everything down again and started the painting. Here's some shots of the mufflers. Have to finish painting the pipes and do some polishing on them then they get put aside until final assembly. Since the wife is working I sprayed the primer then while it was drying clean the fridge for her. Talk about swinging from one end of the job sprectrum to the other.
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Re: Adapting Harley Mufflers

Postby littlebeaver » Sun Jan 30, 2011 5:17 pm

Wow, I like your plumb bob there Santo's...ha ha good one, it works and that's all that matters right.. :lol: Looking pretty darn good there fella.. :D




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