GL1100 exhaust on a GL1200

[cafegoldwang]

So I'm turning a busted 86 GL1200I into a cafe racer. The fairings and everything were already gone when I bought it, and the exhaust had been removed. I painted the exhaust, and went to install it tonight, and realized that it's from a 1100, not a 1200. There's about a 3 inch gap in between the cross pieces. I don't want to buy an exhaust on ebay, so do I have any other options? I could cut the cross pieces off either side, and weld on patches, or make an extension piece. I want to avoid screwing around with the carbs too much as well, this project's on the cheap. I saw something about using harley mufflers, does anyone have experience with that?

[eklimek]

I used the harley mufflers on a 81 gl1100. No apparent running issues. The motor is approximately the same displacement.

HD were a bit loud. I could swear they sounded different left to right. Is that HD copyright?

Ed

[cafegoldwang]

How'd you do it, I can't find specific info on here. Which model mufflers? Did you have to modify the existing exhaust?

[ekvh]

You want to avoid the newer CAT Converter pipes. Older Sportster muffs fit nice, but some Sportsters used different length muffs. Most people would notice if you use a longer connector on the short side.

I bought some Road Kings but they were too long for my tastes. With bags they’re not bad.

I weld mine on solid, but with and adapter good clamps will work.

[eklimek]

Two pieces of exhaust pipe (left and right) to offset the header with the muffler was bent for me at a muffler shop. That lines up the header to the muffler position. Can’t remember exactly, but I think I gave him $10 as it came out of the discard pile. The rest is self evident.

Hope this helps.

[eklimek]

Here you go.

All the best.

[brianinpa]

When I turned my 81 1100 into an 81 1200, I used the 1100 exhaust and it fit the 1200 motor in the 1100 frame .

Anyway, if you are using Sportster mufflers, you want 1996 to 2003 as they do not have a crossover tube hole to weld closed.

[ekvh]

I took mine to the auto parts store and matched a freeze plug that pressure fit in the cross tube holes. Must be five years now.

[brianinpa]

I took mine to the auto parts store and matched a freeze plug that pressure fit in the cross tube holes. Must be five years now.

The older years are getting harder to find, but they are out there.