Factory Two into One Exhaust

[panhead_kicker]

I've never had one bolt right up. Never on any of the Pans and just had to modify a new exhaust system to fit a U model.

That's good to know. I don't want to think it's just me. I've struggled with the 2-into-1 on my pan using Paughco components, but nothing like this. Once I got that sorted out the exhaust goes on and off in 10 minutes. For this shovel I collected all OEM parts (except for clamps) hoping that they would be dimensionally correct (unlike AM stuff I've had).

My dual systems fits nice, and the y-squish pipe is Corso. The rest is OEM.
Havent run the single on the shovel. The y-squish came in two numbers, one for single exhaust, one for dual. Any chance you got the wrong one?

[RooDog]

Fellas....
PH Kicker brought up a good point.
I checked my 1941-78 H-D parts manual, page 156:
It shows the squishy pipe and the Y as one piece, or at least one part number,65538-65, 1965-69 FLs.
Also it shows some spacers, 2 per side, for the muffler support bracket, but it isn't clear exactly where they go, but looks like the center hole, 3rd one back from the front.
Perhaps this is helpful information.
....RooDog....

[Mongrel505558]

I've never had one bolt right up. Never on any of the Pans and just had to modify a new exhaust system to fit a U model.

That's good to know. I don't want to think it's just me. I've struggled with the 2-into-1 on my pan using Paughco components, but nothing like this. Once I got that sorted out the exhaust goes on and off in 10 minutes. For this shovel I collected all OEM parts (except for clamps) hoping that they would be dimensionally correct (unlike AM stuff I've had).

My dual systems fits nice, and the y-squish pipe is Corso. The rest is OEM.
Havent run the single on the shovel. The y-squish came in two numbers, one for single exhaust, one for dual. Any chance you got the wrong one?

I checked my parts catalog that goes up to 84 to get the part number for this. I know they had two dual exhaust setups - one true dual with no crossover (what I had) and one with a crossover. The squish pipe for the true duals doesn't have the port for the rear header. I got it all together earlier today. Got it figured out I think. Everything is on and tight. Now I just have to clean my blood of of some of it.

[Mongrel505558]

Fellas....
PH Kicker brought up a good point.
I checked my 1941-78 H-D parts manual, page 156:
It shows the squishy pipe and the Y as one piece, or at least one part number,65538-65, 1965-69 FLs.
Also it shows some spacers, 2 per side, for the muffler support bracket, but it isn't clear exactly where they go, but looks like the center hole, 3rd one back from the front.
Perhaps this is helpful information.
....RooDog....

That is correct - for the shovel 2-into-1 the squish pipe and Y-pipe are one and that is the part number I bought. The only aftermarket pipe I have is the rear header and that is too long. When it butts up against the horizontal edge of the S-pipe just inside of the port (where the weld is) and I put it into the rear head exhaust port, the S-pipe is pushed way down, where it should sit above the sidecar loop. I took a Dremel and cut about a 1/4" arc in the bottom edge of the rear header and now it all lines up nicely.

[panhead_kicker]

Fellas....
PH Kicker brought up a good point.
I checked my 1941-78 H-D parts manual, page 156:
It shows the squishy pipe and the Y as one piece, or at least one part number,65538-65, 1965-69 FLs.
Also it shows some spacers, 2 per side, for the muffler support bracket, but it isn't clear exactly where they go, but looks like the center hole, 3rd one back from the front.
Perhaps this is helpful information.
....RooDog....

That is correct - for the shovel 2-into-1 the squish pipe and Y-pipe are one and that is the part number I bought. The only aftermarket pipe I have is the rear header and that is too long. When it butts up against the horizontal edge of the S-pipe just inside of the port (where the weld is) and I put it into the rear head exhaust port, the S-pipe is pushed way down, where it should sit above the sidecar loop. I took a Dremel and cut about a 1/4" arc in the bottom edge of the rear header and now it all lines up nicely.

I think you guys both missed my point. There is a y-squish pipe for Single exhaust system, 65539-65, then there is a y-squish pipe for the Dual exhaust system part number 65538-65. I just wondered if you had the correct number for single system.
But that doesn't matter now, sounds like you've got it licked!

[Mongrel505558]

Fellas....
PH Kicker brought up a good point.
I checked my 1941-78 H-D parts manual, page 156:
It shows the squishy pipe and the Y as one piece, or at least one part number,65538-65, 1965-69 FLs.
Also it shows some spacers, 2 per side, for the muffler support bracket, but it isn't clear exactly where they go, but looks like the center hole, 3rd one back from the front.
Perhaps this is helpful information.
....RooDog....

That is correct - for the shovel 2-into-1 the squish pipe and Y-pipe are one and that is the part number I bought. The only aftermarket pipe I have is the rear header and that is too long. When it butts up against the horizontal edge of the S-pipe just inside of the port (where the weld is) and I put it into the rear head exhaust port, the S-pipe is pushed way down, where it should sit above the sidecar loop. I took a Dremel and cut about a 1/4" arc in the bottom edge of the rear header and now it all lines up nicely.

I think you guys both missed my point. There is a y-squish pipe for Single exhaust system, 65539-65, then there is a y-squish pipe for the Dual exhaust system part number 65538-65. I just wondered if you had the correct number for single system.
But that doesn't matter now, sounds like you've got it licked!

No, I did know what you meant. I came across that when I was looking for the pipe. My 58-68 parts book doesn't even show the single piece Y/squish pipe, but it's on page 196 of my 48-84 parts book under single exhaust system, and it's 65539-65. I don't know what the difference is between the two single-piece pipes, but there must be some difference.

[RooDog]

That is correct - for the shovel 2-into-1 the squish pipe and Y-pipe are one and that is the part number I bought. The only aftermarket pipe I have is the rear header and that is too long. When it butts up against the horizontal edge of the S-pipe just inside of the port (where the weld is) and I put it into the rear head exhaust port, the S-pipe is pushed way down, where it should sit above the sidecar loop. I took a Dremel and cut about a 1/4" arc in the bottom edge of the rear header and now it all lines up nicely.
[/quote]

Good deal...
Sorry for this message, it was on hold for an hour while I went to the Aces for some Harley hardware..., But anyway, this was my comment....
Usually having access to a full machine shop helps building a vintage Harley.
This is a lesson guys new to this game need to accept: Nothing goes as well as it should......
....RooDog....

[Mongrel505558]

That is correct - for the shovel 2-into-1 the squish pipe and Y-pipe are one and that is the part number I bought. The only aftermarket pipe I have is the rear header and that is too long. When it butts up against the horizontal edge of the S-pipe just inside of the port (where the weld is) and I put it into the rear head exhaust port, the S-pipe is pushed way down, where it should sit above the sidecar loop. I took a Dremel and cut about a 1/4" arc in the bottom edge of the rear header and now it all lines up nicely.

Good deal...
Sorry for this message, it was on hold for an hour while I went to the Aces for some Harley hardware..., But anyway, this was my comment....
Usually having access to a full machine shop helps building a vintage Harley.
This is a lesson guys new to this game need to accept: Nothing goes as well as it should......
....RooDog....
[/quote]

No worries. Funny, while you were probably posting your message I was at Ace Hardware for a 3-1/2" bolt for the muffler clamp. Also, I'm not new to this game - started out at least 35 years ago with Nortons and Triumphs and then 5 H-Ds (that doesn't mean I'm good!), but I agree that rarely does anything go together as well as expected. Although I have to say that my Norton Commandos were not problematic to put together from bare cases up. Those were stock, except replacing the crappy Lucas ignitions with a Boyer electronic units (kind of similar to the Dyna S). I guess I was naive to think that using OEM parts on a stock FLH would be easy. They say one definition of insanity is to do the same thing over and over and expect different results, or something like that.

[FL54]

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[Mongrel505558]

A2E4F704-30A8-47C0-9244-33C0B5C8F4BB.jpeg

That's almost sacred scripture among the Brit bike crowd. No love for the "Prince of Darkness".

[RUBONE]

I disagree on the exhaust issues. Something in your parts combo isn't right. I have put many dozens of stock exhaust parts on many different models and never had a single issue with factory pieces. Knuckleheads, big Flatheads, Panheads, Shovelheads, 45s, Sportsters, etc for the last 50 years. I have never put an aftermarket exhaust on without issues.

[Mongrel505558]

I disagree on the exhaust issues. Something in your parts combo isn't right. I have put many dozens of stock exhaust parts on many different models and never had a single issue with factory pieces. Knuckleheads, big Flatheads, Panheads, Shovelheads, 45s, Sportsters, etc for the last 50 years. I have never put an aftermarket exhaust on without issues.

The only part that isn't factory is the rear header pipe, and as it turns out that's the one I had to screw around with.