About 3 years ago, I purchased a used set of factory mufflers off ebay, I was curious to see the insides of these factory mufflers. Using a dremel tool I cut the weld at the exhaust end of the muffler. I was able to remove the entire baffle tube from the muffler body. That tube extends from the exhaust outlet to the header end of the body; the inlet end is expanded to slip over the header pipe.
Taking a serious look at this tube, about half way down the baffle tube there is a flat plug between two sets of holes punched on either side of the solid plate, thus forcing the incoming exhaust up through the holes into the muffler body and the back again on the other side of the plate into the baffle tube and out the exhaust end of the muffler.
After reading much material on muffler design and theory, I cut the tube in half on the inlet side of the baffle plate leaving the expanded end in tact. Turning the remaining tube 180 degrees, reattaching the shorter baffle tube to the exhaust end of the muffler. You can either drill and bolt the baffle or tack weld it back in.
The result after 3 years of using this system has been very satisfactory. The tone is very acceptable, however, somewhat more noticeable than factory. Under full throttle, it becomes very noticeable, but nowhere near drag pipes. Around town you hardly get noticed by the locals. Every once in a while, I’ll get a wild hair and reinstall some old Screaming Eagle turnouts but I always wind up going back to these mufflers.
Price wise, this costs about 3 hours of time and no bucks, making that first cut takes about 2 hours to commit to. My 2 cents worth and two cents is a lot cheaper than a set of new mufflers.
). The performance is much better too with more muscle at lower revs.
