DIY: Installing baffles in muffler

[Stevenc150]

...is that the valve is used to control EPA noise levels rather then for tuning, back pressure, or torque. Anybody care to chime in on the issue. My butt dyno seems to confirm this as I noticed an increase in torque across the board with the valve wired open.

An actual Dyno run comparing the exhuast servo operating normally on one & exhaust servo wired open would reveal the truth. There would be some torque loss in the just-above-idle and mid-range; (assuming the bike is all stock). The servo was put on there when Stock, to increase torque at the predetermined throttle positions and less for the EPA reasons.

 

[Nuage420b]

i think the baffles are 12-14 inches? I had planned to do the cheap route and drill holes today but I have a sick baby to take care of! i swear every time i have set aside time to do this mod stuff pops up! lol. i just can't see paying that much for something I can make myself. I think i'm going to do the 1/4" holes spaced about 3/4 inchs apart and go straight down through the top and bottom. Then do the whole wrapping and packing.

 

[lawdog]

I had the baffles cut down to 12 3/4 inches.

As far as the tips go I haven't noticed a difference in temps of the tire with the infrared thermometer from the exhaust. Both while idling or after a ride. I have never seen any oil or fluids come out of the exhaust personally so I am not sure on that one. Of course if you think about the big scheme they are still in the same location only pointed down instead of out. If they were mounted closer to the tire or pointed inward I think the exhaust would hit the tire more. As it stands they are on each side of the tire. Kind of hard to see from the pics.

As far as the exhaust valve goes I have been talking to Erik Buell about it messaging on FB. When I get more time I will post his reply. He is a cool guy and very down to earth.

Edit: Correction per request

 

[lawdog]

So I became friends with Erik on facebook and asked him about the exhaust valve. He stated the valve is used for the epa mandate for the db limit at certain rpms. That is why there is the stamping in the muffler per the EPA requirements.

He also said they tuned the bikes using the exhaust valve to maximize torque as well.

So there you go. The valve is for the EPA noise laws and they programmed to make use of the valve as efficiently as possible to increase torque.

 

[lawdog]

Ok so I finally got a video of it. Sounds pretty much just like a sportster!

I am working on making another muffler which I will probably sell since I have an extra stock muffler laying around.
Brett

 

[Nuage420b]

is that with the exhaust valve tacked open or functioning?

 

[lawdog]

Exhaust valve wired open.

 

[Nuage420b]

it sounds loud but not as loud as some others. does it thump your chest? or ring you ears?

 

[Clutch]

where did you buy the baffles?

 

[lawdog]

I bought the baffles at American Legend Motorcycles as that was the cheapest place I could find them. The sound is a thumpty thump thump at idle. My crappy camera doesnt record audio very well so I didnt really capture it. I have only heard a Jardine on a XB9 and it is not as loud as the Jardine. I would like to compare it to other exhausts once I meet up with fellow Buellers.

As far as ringing in the ears I wear earbuds when I ride so no. But cruising around town there is no ear ringing. Its more deeper and mellower. Definitely turns heads as most people are like "WTF" just passed me!

If you wanted to go deeper sound I would look into 2.25" baffles but then you run the risk of having a soggy midrange with the larger baffles. 2" seem to be a good compromise between sound and torque. Honestly if I didn't have this giant sucking sound like my bike is trying to suck the jacket off my chest it would be perfect. I hate the loud intake noise but I want performance. When I wear earbuds I dont hear the intake but only the rumble of the exhaust.

 

[lawdog]

If you have heard a D&D I would imagine a D&D and mine would sound pretty much the same. Its hard to compare exhaust sound on Youtube but the design principle is the same.


The way I see it there are 3 times of mufflers you could design for our bikes.

1. Chambered - Hawk, race, stock.... sound is dispersed through bends, chambers, and pipes (Flowmaster style)

2. Baffled - D&D, Mine.... sound is muffled by exhaust packing around tubes (glasspacks)

3. Hybrid - Drummer, Jardine.... sound is dispersed in a large chamber or mutiple chambers and muffled by packing lining the chambers (Dynomax Superturbo)


I personally like the sound of fiberglass packed mufflers like the Dynomax. I am currently working on another one of these mufflers except I am creating a chamber at the front. A sort of hybrid as you will. Then I am going to try different length and width baffles to see what differences in sound it makes. Run which ever one I like better and sell the other one on here.

 

[lawdog]

Idling in the parking lot at work. Don't mind the radio traffic in the background. LOL. Forgot to turn my portable off.

 

[chiligrease]

general question, any tips for repacking a jardine can? also i notice a considerable ringing in my ears from this exhaust. the port dumps out directly on the back tire, is this an issue? could be my helmet is too big, anyone have any cures, suggestions?

thx

chili

 

[lawdog]

As far as the actual process of repacking the jardine start with a search as there many previous topics on it.

Ear ringing is normal with a louder aftermarket exhaust. Not good for your hearing! I wear earbuds when I ride.

The best packing to use is Silent Sport Premium but it is expensive. The tighter you pack it the longer it will last but it will be louder. If you pack it looser it will be quieter but blow out quicker.

Honestly if a Jardine is too loud I would repack it and see if you like it. If it is still too loud then sell it and try another muffler. Jardine is one of the louder mufflers.

 

[cyclic]

Just get the Jardine insert, or make your own. HUGE difference. Still nice deep and agressive, but no longer causing any hearing damage. Less than $40