fulsac CVO baffles

[dirtdobber]

Has anyone tried to fit the fulsac cvo muffler core baffles?
I really would like to use these if they will fit the free mufflers.
He carries his own line of mufflers but they are 30 inches long which is too much for me. From the measurements I took the end of the cvo mufflers are very very close to the same as the free mufflers are. This is with out the end caps mind you.
dd

[dirtdobber]

Smoeone posted that they used the fulsac baffles. Cant find the tread and post. I was hoping they would post here. I did find out the cvo baffles are 25.5 inches long. May have to take the risk and see if I can make them fit.

[consitter]

I used fullsac baffles, but they weren't labeled as CVO as I recall. The dealership put them on. I like them really well. The sound has improved as they've 'broken in'.

BTW, they used the factory mufflers and just replaced the baffles. The factory ends were cut off, and fullsac ends replaced them. They look really good.

[dirtdobber]

I could not remember who posted it but it could very well have been you. I'll take the risk and give em a try. I can fab em to make them work.
Thank you
DD

[consitter]

Here are the baffles that are in my mufflers...

http://fullsac.com/product/oem-hi-flow-muffler-kit/

They used the 2.0 option, which is what the guy that started fullsac recommended. Call the company, they are very helpful and will tell you what you need. Not necessarily what is the most expensive.

[dirtdobber]

Thank you
Ill call em Monday to see which i can use. The stock mufflers makes it had to get a good tune because of the packing. It keeps stopping up the vacuum

[dirtdobber]

Fulsac are really cool to deal with. They have put together a cvo package for our free. I have to weld the large bolt in ends to fit. Which is what i wanted any way. I'll post when I get things worked out with some photos.
I like a fun project

[consitter]

Fulsac are really cool to deal with. They have put together a cvo package for our free. I have to weld the large bolt in ends to fit. Which is what i wanted any way. I'll post when I get things worked out with some photos.I like a fun project

Glad to hear. Can't wait to see the pics.

[dirtdobber]

They put together a kit for me. I will post my results for others in case they may be interested. I will alos forward my results to fullsac.
This will be fun.

[consitter]

When I get home from our camping trip, I'll post a pic if what the slash cut ends look like installed, if you'd like. We'll be home tomorrow.

[dirtdobber]

It isnt necessary as i am ggetting only a kit somewhat.
Its only the fluted baffle for the cvo's and 4 of the ends for the muffler case uninstalled. I did not want that kit with the endcaps.
Unkowing what may need to be done for fitment they did this for me. This way it will be a lot easier to fit correctly. It will look factory when finished, or very close to it

[consitter]

[dirtdobber]

Got the baffles in today here is the kit they fixed up for me.


Getting things ready to start tomorrow.


This may be easier than I originally thought. The ends fit perfect, kinda tight but doable easily. A little polishing and they fit like a glove.

[consitter]

Those look exactly like what was installed on mine. I really think you'll be pleased with the results.

Are you mapping your engine?

[dirtdobber]

This is 2 different sets put together.
The baffles are for the cvo performance baffles and the flanges from the set you got. It was a lot lower cost for me to do it this way.
It has been dyno tuned already. It's running a shade rich for touring. I am hoping it will lean it a shade. It's my MPG I need up slightly.
If it doesn't run like I think it should I am going to try something different for tuning.

[consitter]

This is 2 different sets put together.
The baffles are for the cvo performance baffles and the flanges from the set you got. It was a lot lower cost for me to do it this way.
It has been dyno tuned already. It's running a shade rich for touring. I am hoping it will lean it a shade. It's my MPG I need up slightly.
If it doesn't run like I think it should I am going to try something different for tuning.

Mine is running a little rich too. It cools it down some, but not much. You may have already said, but have you removed the cat?

[dirtdobber]

Yes I removed the cat before tuning.
It runs great, and I am surprised how well it does run. Plenty of power for any riding we do.
Just not that happy with mpg I get. I have gotten it up to 31 mpg from the 27 mpg I was getting.
It was not dyno tuned when I did every thing. Had a surge off and on when riding. Had it dyno tuned and the surge is gone. My mpg dropped dramatically. Went from 36-37 mpg to 27 mpg.
We take several long trips out west so mpg really matters sometimes. At this point I can get 150 miles to a tank with some left over, not much but some.

I am use to our Goldwing trike with a Roadsmith kit with 2 fuel tanks.

[dirtdobber]

Keep getting interference with my work. I reckon I'm the only one at home that can do anything. LOL
Got the right side finished, working on the left.
Here is what is inside the muffler:


Baffle


There were some nasty weld that I had to remove to get the baffle out. They were just messy welds in the way, not holding anything on.

[dirtdobber]

Got finished and took a test ride to the store.
I am more than satisfied It sounds great, deep bassy sound.
Oh if any one is going to change baffles, look at the photo with my machine bits. One of them is rounded on the end. That is the one you want to use. That took out the weld quick. One the first one I tried different bits to cut the weld but the rounded end one was the one. 20 minutes tops. Could not find a hole saw that would fit right. It was either to big or to small.
These are suppose to be 4 inch but a 4 inch hole saw would not fit but the 4 inch baffle end did. go figure.
The diameter is 3 13/16 inch
I am a happy camper this evening.

[consitter]

Congrats on a job well done!