Posted by Capt. Capsize on January 09, 2002 at 15:31:26:
In Reply to: Muffler drill through posted by Jaz on January 09, 2002 at 12:00:41:
No, No, don't do it. My Savage sounded like a wheezy old man so I thought drilling out the inner baffle would make it sound better. Wrong, it just sounded louder, it then sounded like a wheezy old man with a bad cough. What seems like a baffle in there is plate that separates the inner baffles from the outer baffles. If you put a hole in it, you give the exhaust a straight path to the outside.
If you want a good but not offensive sound and more power at low cost and long term durability try this. Go to your local independent Harley shop and ask if they have a used muffler in their toy box preferably a short cigar shape. Then cut the weld at the end to slide the baffle out to where you can drill the baffle holes about 30% oversize. Then take the muffler to an EXPERT welder that can weld it back in without burning the chrome. This is what I did, it cost me $15 for the muffler and $26 for the welding. It sounds great, and along with the carb and air box mods the bike runs stronger throughout the power range. It used to have a top speed of 85 now runs past 95 don't know how much past, bike is too light for these speeds.