| Author |
Message |
    
Blake
| | Posted on Thursday, March 06, 2003 - 05:29 pm: | 
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I received a recent plea for help via email. Thought it might be worthwhile including in the KV. In short, replacing the welded tabs/brackets on aftermarket slip-on mufflers with separate clamp supports eliminates the cracking and tearing problems some have suffered.
The related correspondence follows...
Blake,
Could you please e- me any pictures, or a diagram to illustrate how you repaired your Borla. I am at wits end trying to keep my exhaust intact.
Thanks,
JV
JV,
I've never had to repair my Borla other than to add the beefier front T-Bolt
clamp.
Beefy T-Bolt ClampYou can find the beefy T-bolt clamps at http://www.mcmaster.com; part
number and info are...
Part Number 5443K29
Type 430 SS Band Heavy Duty T-Bolt Clamp
2-11/16" To 2-7/8" (68-73 mm) Diameter Range
$6.04 EA
The above will work with the 2-1/2" diameter collector version of the Borla.
If you have the 2" collector version you will probably need part number 5443K27.
Do NOT use the version with the stainless steel bolt. It WILL gall and
seize. The above part numbers are for the correct zinc plated bolt versions. 
See http://www.badweatherbikers.com/buell/messages/3842/16413.html?#POST128942
for pictures and discussion. Apparently the OEM race header support shoe is
part number S1121.G and costs a crazy high $39. You might ask Borla if they
have any of their muffler support hardware available.
My 2-1/2" diameter inlet Borla CF muffler did not have integral mounts welded
to it. The front was supported with a shoe type pipe support bracket
resembling the one that is supplied with the race kit header. Basically it is
a reinforced/gusseted L-shaped bracket (as viewed from the left side of the
bike) that hangs down from the support clevis/lug with the bottom of the L
curved to fit over the muffler inlet pipe just forward of the can. Apply heavy
duty T-Bolt band clamp and there you have it.
The rear was suspended by two pieces of chromed flat bar bolted to a beefy
chromed pipe hanger clamp as shown in the attached sketch. 
Borla Rear Muffler Hanger
I would take a
picture, but I've removed the Borla in favor of a race header and muffler for
track duty. The belly pan would not fit well enough over the stock header and
Borla can. If you look around McMaster-Carr's online catalog, you should be
able to find what you need or at least something close that might require
minimal modification.
I'll post this on the board in the KV - Exhaust topic. Please let us know the
results of your efforts on this.
Good luck,
Blake
Blake,
I am so sorry!
I found out (on line) I really have a Buell Carbon Fiber Muffler.
I thank you for your very quick response.
I should have done my homework and not wasted your time!
Would it be to coldblooded to ask the same question, about the Buell broken
straps problem?(I have a 96' S1 Lightning)
I would understand it if you told me to,"Take a ride on my
Buell!!!!!!!!!!!!!!!",.
Once again thank you very much,
JV
JV,
No worries. You might try hacking/grinding off the tabs on the muffler and go
with the type of hanger setup like the Borla uses. That eliminates the tab
weld breakage issue.
Let us know how it turns out.
Blake
I'd add just a few more things... Adding a T-Bolt clamp at the collector to attached to the header support tab on earlier Buells helps reduce vibration at the front hanger. Newer ('99+?) Buell twins can add the tab to also achieve the extra fixity provided by such a setup. It may be advantageous to rigidly secure the front hanger to the Y-bracket. I agree with Aaron, that the less vibration allowed, the better. In assembling the system, get it all to fit while keeping the fasteners just hand tight before torquing any of the bolts. Good luck all. |
Rick_A
| | Posted on Friday, March 07, 2003 - 01:46 am: |
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The T-clamps supplied through Buell/H-D are pretty cheesy. I'm gonna have to get me one ah those heavy duties for backup. |
Blake
| | Posted on Friday, March 07, 2003 - 02:07 am: |
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Yep, mine kept starting to tear due to the sharp edge on the Borla's L-bracket clamp support. BTW, you can get those clamps from McMaster Carr too, cheap.
The clamp Buell uses on the collector, part number 65297-95Y, is stout as heck, more. But it really only fits a very limited diameter, not much of a range. Not sure if it would be useful anywhere but at the muffler/collector joint. I tried shimming one once with strips of lead sheet. The lead melted. D'OH! LOL! |
Italialaw
| | Posted on Tuesday, June 08, 2004 - 10:57 pm: |
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Blake and anyone else who has used the above t-bolt clamp for McMaster. See my pics. Will the t-bolt clamp work for the front and rear of this old D&D pipe? The clamp interests me because the mounting tabs are chrome and I'm paranoid they will break easily. If the McMasters work, does anyone recommend putting the bolt through the tabs for extra security, or just saw those tabs off?
Thanks! |
Italialaw
| | Posted on Tuesday, June 08, 2004 - 11:04 pm: |
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pics 1&2 |
Blake
| | Posted on Wednesday, June 09, 2004 - 10:55 am: |
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Try pasting,,,
\image{My D&D Pics}
into your post for each photo you wish to post, or click on the "Upload Attachment" button below.
When you click on "Post..." you'll be asked to upload your photo file(s).
Make sure your photo files are less than 60KB and no more than 600x800 pixels in dimension. |
Blake
| | Posted on Wednesday, June 09, 2004 - 11:00 am: |
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FYI... I tried supporting my race exhaust at the muffler using the same technique, the beefy ring clamp would crack and fail, but it would still support the tailpipe/muffler. I think a beefier version might work better. I'm now back to using the Borla and am supporting the tailpipe using two flat bars and a spare race header support shoe and the clamp shown above. Is working well, seems rock solid and resistant to failure. |
Simond
| | Posted on Wednesday, September 29, 2004 - 01:16 pm: |
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Blake,
I've just been trawling through the archives for some advice on fitting a Borla muffler. I've picked up a s/h carbon 2.5" Borla and will be fitting it at some stage to my X1.
I'm happy that I have enough hardware for the rear mount but the front is less clear. The front pipe obviously had a bracket welded to it at some stage. I'm not sure if this was original or not but it has been removed and I have no intention of replacing it.
I also have a shoe (not unlike that used to mount the race header) with two tabs that are clearly designed to locate with the front muffler mount. The difficulty I have is that this shoe is designed to fit to a straight section of pipe but the Borla front pipe has no straight section - it curves from the header to the entrance to the muffler without ever straightening up. The shoe, therefore, will not sit on the pipe.
Does it sound like I have a different muffler to you or have I missed something? I may use something similar to the rear mount in your diagram above to mount the front of the pipe with a suitably angled strap.
Apologies for dragging up an old thread. Do you have any pictures of the Borla mounted to your bike?
Thanks for any help
Simon |
Sandblast
| | Posted on Sunday, November 07, 2004 - 07:47 pm: |
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Blake- Sorry if I am beating a dead horse, but does the circle clamp in the above photo go around the steel behind the carbon fiber? I just got a Borla from the classified section, and it has no mounting hardware at all. I have never seen one in person, and would like to get how I am going to mount it squared away before it gets here. (hopefully in a few days).
I am a little confused as to how the clamp for the front that you recommend fits to the front exhaust mount (mine is the new upside down Y style, I dont remember seeing what the race header support that you refer to looks like). Anyone have a photo of the whole set-up?
Mounting a pipe seems kinda simple but I have learned from reading here if you dont do it just right there are going to be issues...
I am really exited about the Borla, I have rejeted my carb and added a Hypercharger from Al, but have always had the stock pipe. Will I notice a power difference? |
Captainkirk
| | Posted on Sunday, November 07, 2004 - 11:28 pm: |
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Sandblast:
I'll try to post a picture of the race pipe setup, if that helps |
Sandblast
| | Posted on Sunday, November 07, 2004 - 11:32 pm: |
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Thank you, I see the L Blake was talking about now. Hmmm... Might need one of those L thingies... |
Sandblast
| | Posted on Wednesday, November 10, 2004 - 09:41 pm: |
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Any one else have a picture of how they supported the front of a slip on? I'm getting the Borla carbon fiber slip on. It seems easy enough to make the back mount like Blakes drawing, but I would like as many ideas as possible about the front part. Thanks. Captain Kirk, that L shaped bracket is in the Race kit? |
Captainkirk
| | Posted on Wednesday, November 10, 2004 - 10:04 pm: |
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Yep. P/N is 65455-96Y Header Support. Might be available separately, if you're lucky. |
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How to Stop Support Tab Failures on Slip-On Mufflers.