Fullsac Exhaust System Install

[hulkss]

With all the talk about exhaust systems, I had to get in on the fun. I decided to buy a stock appearing 2-1-2 performance exhaust that made use of the stock heat shields. I like two mufflers out back and I want good ground clearance with good engine performance.

Fuel Moto and Fullsac make similar headpipe systems combined with a proven dyno tuned set of four inch mufflers. I've had good luck with ceramic coated steel headers so no need for stainless steel.

Jackpot (Fuel Moto) has developed 4" mufflers with an asymmetrical baffle system that allows them to use the right muffler as the primary muffler.

Fullsac uses the same baffle on each side in re-cored CVO mufflers with a new DX collector designed to create equal flow to the left side muffler.

I chose the Fullsac symmetrical flow solution. I like the concept of getting the same flow through each muffler. I selected the 1.75" muffler cores that make the best low end torque and are more tame on the sound level.

With the stock heat shields in place, the exhaust system appears showroom stock (for a CVO). It produces a good Harley sound without being too loud I'm told. I'll know after I get some miles on it.

 

[hulkss]

I found an unused set of 2011 CVO take-off mufflers on eBay for $250. I put a set of Fullsac 1.75" cores in them which is the same diameter as the headpipes.

Two 1.75" cores have the same flow area as a single 2.5" core in a 2-1 exhaust. The biggest difference is that the two muffler solution is going to be quieter.

I reused the factory 3” diameter screens that hold the muffler packing to the outer walls of the mufflers. I put in new 1/2" Techmat fiberglass packing. The trick to good performance is to NOT have the packing wrapped directly around the muffler core. The picture shows the 3" diameter screen without the 1.75" ID core that goes down the middle.

The right most picture shows the four core sizes Fullsac offers. I used the smallest ones. The bigger cores are for louder, not for more performance.

 

[streetsurfer]

Nice pics and torque with out noise can be fun!!

 

[OldMike]

Thank you for posting, I just got my eBay CVO mufflers for the option of doing the 1.75" mod.
I have the Fuel Moto 2-1-2 head pipe, even with a full size crossover, I think most of the exhaust goes through the right muffler following a path of least resistance.

 

[Spazz]

Nice info and good details Hulkss....

 

[BluesBelly]

Hulkss,
Similar to your mods I purchased a pair of 2014 CVO mufflers on ebay for $200. Starting in 2012, I believe, the baffles were changed from the one you have pictured. The new baffles are the same for both left and right sides of the bike. Instead of being ,half flattened, and welded in the middle the new style baffle is basically the same configuration as on the stock 103" SG but flow much better. CVO baffles consistist of 1.75 dia perferated tubing straight through (picture the fullsac baffle) with a tail end baffle of smaller diameter insterted. The tail baffle is about six inches long and has the four sided termination pucker to seal it from the larger main perferated chamber. In the sides of the tail baffle are drilled six rows of four to a row 3/8" holes (24 holes) as opposed to four rows of four 3/8" holes (16) on the smaller diameter stock SG pipes. The flow is geared to a CVO 110 inch engine so works great on a SG 103. Doing the math the open Fullsac 1.75 dia baffle is 2.4 sq in and the stock HD baffle with 24, 3/8" holes equals 2.65 sq in. In simple terms the baffle has more flow capability than the open pipe itself. So aside from the obstruction from the tail baffle itself the stock CVO muffler flows very well and the muffs are the same on each side of the bike.

The reason I brought this to light is for those that want an attractive quiet muffler with good flow and at a resonable price.
The CVO muffs can still be disasembled and re-screened and re-insulated drilled and reinstalled just like the Fullsac offerings and can be swapped out for the Fullsacs if more noise is needed. I for one have put too many miles on too many noisy bikes and need quiet. Not to say I still don"t appreciate a nice sounding bike my favorite of which is a Shovel with drag pipes. Ahhhh! The Old School.

Low & Slow

Blues

 

[Tom O.]

Awesome! If I was to go with a dual set up again I would definitely look at the Fullsac and something similar behind it. Nice write up!!

 

[hulkss]

I have the Fuel Moto 2-1-2 head pipe, even with a full size crossover, I think most of the exhaust goes through the right muffler following a path of least resistance.

Fullsac worked on the X-Pipe and elbow design to get the flow to split 50-50 with the same muffler on each side. The Jackpot design appears to have a much tighter bend to the cross-over pipe.

 

[hulkss]

Starting in 2012, I believe, the baffles were changed from the one you have pictured.

Yes, the CVO muffler design did change in 2012 and later. 2011 and earlier have the screens needed to use Fullsac cores. Fullsac sells screens if you have a newer CVO muffler to re-core. All of them are the same internally on both sides as far as I know. They are opposites externally just for fitment on the bike.

The reason I brought this to light is for those that want an attractive quiet muffler with good flow and at a resonable price.

Yes, stock CVO mufflers work just fine and are great for the music loving crowd. I chose the Fullsac 1.75" cores based on well documented performance, no need to guess what works. I want a bit more exhaust note too.

 

[OldMike]

Hulkss,
Similar to your mods I purchased a pair of 2014 CVO mufflers on ebay for $200. Starting in 2012, I believe, the baffles were changed from the one you have pictured. The new baffles are the same for both left and right sides of the bike. Instead of being ,half flattened, and welded in the middle the new style baffle is basically the same configuration as on the stock 103" SG but flow much better. CVO baffles consistist of 1.75 dia perferated tubing straight through (picture the fullsac baffle) with a tail end baffle of smaller diameter insterted. The tail baffle is about six inches long and has the four sided termination pucker to seal it from the larger main perferated chamber. In the sides of the tail baffle are drilled six rows of four to a row 3/8" holes (24 holes) as opposed to four rows of four 3/8" holes (16) on the smaller diameter stock SG pipes. The flow is geared to a CVO 110 inch engine so works great on a SG 103. Doing the math the open Fullsac 1.75 dia baffle is 2.4 sq in and the stock HD baffle with 24, 3/8" holes equals 2.65 sq in. In simple terms the baffle has more flow capability than the open pipe itself. So aside from the obstruction from the tail baffle itself the stock CVO muffler flows very well and the muffs are the same on each side of the bike.

The reason I brought this to light is for those that want an attractive quiet muffler with good flow and at a resonable price.
The CVO muffs can still be disasembled and re-screened and re-insulated drilled and reinstalled just like the Fullsac offerings and can be swapped out for the Fullsacs if more noise is needed. I for one have put too many miles on too many noisy bikes and need quiet. Not to say I still don"t appreciate a nice sounding bike my favorite of which is a Shovel with drag pipes. Ahhhh! The Old School.

Low & Slow

Blues

Thanks for all the research, my stock SGS muffler baffle has 12 holes (6 x 2), the CVO's I just installed have 24, twice as much. I'm looking forward to hearing/running this exhaust since I like quiet.

 

[OldMike]

"Fullsac worked on the X-Pipe and elbow design to get the flow to split 50-50 with the same muffler on each side."


I see, thanks.

 

[Bones]

Hulkss,
Similar to your mods I purchased a pair of 2014 CVO mufflers on ebay for $200. Starting in 2012, I believe, the baffles were changed from the one you have pictured. The new baffles are the same for both left and right sides of the bike. Instead of being ,half flattened, and welded in the middle the new style baffle is basically the same configuration as on the stock 103" SG but flow much better. CVO baffles consistist of 1.75 dia perferated tubing straight through (picture the fullsac baffle) with a tail end baffle of smaller diameter insterted. The tail baffle is about six inches long and has the four sided termination pucker to seal it from the larger main perferated chamber. In the sides of the tail baffle are drilled six rows of four to a row 3/8" holes (24 holes) as opposed to four rows of four 3/8" holes (16) on the smaller diameter stock SG pipes. The flow is geared to a CVO 110 inch engine so works great on a SG 103. Doing the math the open Fullsac 1.75 dia baffle is 2.4 sq in and the stock HD baffle with 24, 3/8" holes equals 2.65 sq in. In simple terms the baffle has more flow capability than the open pipe itself. So aside from the obstruction from the tail baffle itself the stock CVO muffler flows very well and the muffs are the same on each side of the bike.

The reason I brought this to light is for those that want an attractive quiet muffler with good flow and at a resonable price.
The CVO muffs can still be disasembled and re-screened and re-insulated drilled and reinstalled just like the Fullsac offerings and can be swapped out for the Fullsacs if more noise is needed. I for one have put too many miles on too many noisy bikes and need quiet. Not to say I still don"t appreciate a nice sounding bike my favorite of which is a Shovel with drag pipes. Ahhhh! The Old School.

Low & Slow

Blues

BluesBelly...I had a 1957 Pan with straight pipes. The sound of that motor haunts me to this day.

 

[BluesBelly]

BluesBelly...I had a 1957 Pan with straight pipes. The sound of that motor haunts me to this day.

i

Bones,
I hear ya' loud and clear Brother! Well as good as I can after all the years of straight pipes!
My tetosterone flare ups are fewer and farther between so I'm content with quiet. LOL!
Can't shake Old School though!

Blues

 

[shortguy]

thanks for the write up hulks, I have the fullsac pipe in the garage now. I did my research as well and glad someone else can verify my findings.

 

[graywolfhd]

Very happy here too with the Fullsac DX head pipe. Looks stock, but not so much. Better flow and definitely alot cooler than with the stock one.

 

[Tom O.]

hulkss do you have any video of the new set up that you can share? I am thinking this may be the way to go. Just trying to see how those baffles sound.

 

[hulkss]

Here's a good video:

Another:

 

[OldMike]

The CVO mufflers have a nice note.

 

[Tom O.]

hulkss do you think yours are any louder than the video with the DX head pipes you have? Sounds pretty mellow in the video you posted. Not that its a bad thing by any means.

 

[hulkss]

I don't know how to compare to the video. Go search here, lots of discussion and video links: cvoharley.com