Hello All,

Since this forum has helped me many times I decided to take a couple of minutes and share a "Do-It-Yourself" project.

NOTE: I left the catalytic converter in place.

When I picked up my new Road King I loved everything with the exception of feeling like I was ridding a "metric or electric bike". I have been ridding for 30+ years and honestly, the two major things that attracted me to a Harley was the individuality and the sound of a Harley opened up under hard acceleration.

So I knew "MOD #1" was going to be slip on or full exhaust. After shopping around I was getting ready to spend $626 -$1,025 for a better sound. The problem is unless you have someone who has that particular slip-on, your left with hoping they are the sound you were hoping for. So I decided to do a "baffle ectomy" and see what result I would get. It was extremely simple with the right tools and took under 1 hour.

For the record the "left" and "right" side are "EXACTLY" the same. Unlike past models the right side baffle was a bear to move because it was larger than the opening and you had to sawzall slits to compress the baffle to get it out of the pipe. This is not the case with my Road King.

First the tools you will need:
(1) 3" Hole saw/cutter for metal
(2) Pillars, long screw driver
(3)Cutting Oil
(4) High Torque drill 1/2 drive (Variable Speed)
(5) Patience
(6) Gloves - The packing is fiberglass and you will not have a good experience unless you wear gloves.

Start by pulling off your bags.

With your 3" hole cutter center as best as you can. You will get some chatter because the metal baffle you are trying to cut/remove is conical in shape and the hole saw will struggle to find a center. If you go slow after a couple of minutes it will start to make a path and in no time you will cut thru, it is thin metal. Take your time, slow and steady and put a little oil on the blade a couple of times.

3" Hole Saw





The Break Through;


After you punch thru you can literally grab it with a pair of long needle nose pliers or, just use your fingers.



Now you can go two different ways at this point. On the right side I started to loosen the packing with a long screw driver and using a pair of pliers. I started twisting and pulling. That worked but, the packing would hang up on the sharp edge of where you separated the baffle. I took me 15 minutes to remove because it kept breaking/shredding off.

On the left side I followed the same procedure but, before pulling the packing I used a grinding stone (see below) on a drill and broke the sharp edge. The packing came out in 2 pieces and less than 5 minutes.

I like this stone because it help not wanting to come out and risk damaging your paint/chrome. $3.89


Packing Removal:
After the packing was removed I finished cleaning up the rough areas to look factory new. I then tapped off the ends of both pipes and painted it with RUST-OLEUM high heat flat black. You can find it at Lowes and is commonly used on BBQ's.



So the final result/review:



Hands down I am completely satisfied with the result. I will not be spending money on a set of slip-on's and will use my money for something else.

The tone is very deep and throaty. At cruise speed you hear a slight rumble but "zero" drone. When you crack the throttle it sounds like a Harley supposed to sound. Not obnoxious but, loud enough to put a smile on your face.

This will void your muffler warranty.

Good luck and enjoy the ride.

 

Alrighty then......

 

Warranty?

 

The muffler bearing warranty is void.

 

Did you lose any hp or torque from the lack of back pressure. I've got an 18 road king im thinking about removing mine

 

I didn't notice any power loss, loud for sure. I did get a noticably good boost in power gutting the cat and running the HD tuner, but went all out on a Cobra header and slip-ons and HD Race tuner (wide band o2 sensors) and a better air filter (that don't look like something of a briggs and stratton riding mower). I think if I had to do it again I would start with cutting the center hole bigger and leaving some of the packing alone, idk just a idea.

Btw, if anyone does it and hates it I have a set of black factory slip ons and head pipe with cats in it still...make me a offer.

 

That will most likely affect your warranty. Check your owner's manual for details.

 

What is your thoughts for why you would want to leave some packing?

 

It had a bit of a tin can sound to me after awhile. Not bad, and i think a little fiberglass in there would make it sound less like a hollow pipe. Idk. Just wish I would have had more patience and tried before emptying them out. Experimenting vs make it loud af now.

 

Warranty...pfff...HD is gonna void your warranty for having a different sticker on the damn thing anyhow.