Alignment-problems Muffler/Y-Pipe/Exhaust

[DeltaElite]

Something must be wrong with my Exhaust-Setup but I can't figure out what.

On my 62FLH the Muffler-Strut was mounted the wrong way, which came to my attention when I tried to mount the center stand.

After switching the muffler-strut from the inside to the outside I realised that the previous owner had cut the rearwards pipe of the y-pipe. That was probably because he used a later-style Repop muffler. With that being done it was impossible to attach the muffler because it would have contact with the mounting screws of the muffler-strut.

So I ordered a corrcet Muffler and a new y-pipe (both from Gasbox).

Now I was able to mount the muffler-strut and the center stand correctly while being able to attach the muffler to the y-pipe as well.

Problem is now with the connection between front of y-pipe and squish. Either I get the elbows, squish and Y-Pipe aligned or I get the muffler and Y-Pipe aligned. If I try to get the whole system aligned I either end up with y-pipe to squish out of limits or the front elbow not sitting correctly on the front cylinder outlet.

Maybe you can see from the pics if there is any error source I overlooked?

[panheadrider1961]

Front pipe missing mid mount clamp to frame down tube allowing pipe to be pushed up and out
It is a must have also will not allow pipe to slip off exhaust spigot, AM parts are troublesome sometime on exhaust ,leave the pieces lose and work back and forth

[Mongrel505558]

There's a particular sequence you have to discover for it to go together, and, as was said, aftermarket exhaust components often require some "massaging" to get them on. I second the comment regarding the front pipe clamps. They definitely are a must have. Maybe you have them and just haven't gotten to that point yet. For me they're the last thing to go on, once everything else is aligned and tightened. Good luck.

[Excalibur]

I documented my '61 exhaust install, might be of help for ideas. Good luck.

[DeltaElite]

Actually not a single clamp (except Muffler) is on.

What I couldn't figure out so far is : where are these clamps mounted to?

I can see them in the parts book but nothing said in servicemanual and I can't see any fixing point on the frame

[panhead]

Exhaust pipe clamps

See also the Gallery for pictures.

[RooDog]

Front pipe missing mid mount clamp to frame down tube allowing pipe to be pushed up and out
It is a must have also will not allow pipe to slip off exhaust spigot, AM parts are troublesome sometime on exhaust ,leave the pieces loose and work back and forth
[/quote]

Muffler Clamp.06.JPG (117.3 KiB) Viewed 848 times

[RooDog]

Harley Swingarm Frame.jpg (13.96 KiB) Viewed 839 times

Notice the upright tab on the lower, horizontal tube, right hand side. It is a mounting point for the squish pipe, but yours is missing both the tab on the frame and the requisite tab on the squish pipe for secure mounting.
Especially on a Panhead the exhaust must be clamped securely in many places to avoid misalignment, and damage to the head port spigots. The clamps, no matter how tight, at the head ports do little to secure the exhaust system. If everywhere else is secure, the head clamps are not even necessary, though it is not recommenced to omit them.

Harley Squish Pipe.jpg (5.42 KiB) Viewed 839 times

[Andygears]

As others have said, that frame bracket in the middle needs to be there, it locates everything. Also, your rear cylinder pipe looks odd. Instead of a curved pipe, it looks like a pipe with two bends in it? A stock pipe can be rotated to move the exhaust inward slightly. And, once you get a reasonable fit, mark everything with sharpee marker, disassemble it and seal all the joints with high-temp silicone seal, the only place you want silicone on your Panhead.

Andygears

[panhead]

P1020842.jpg (95.39 KiB) Viewed 821 times

[DeltaElite]

Harley Swingarm Frame.jpg

Notice the upright tab on the lower, horizontal tube, right hand side. It is a mounting point for the squish pipe, but yours is missing both the tab on the frame and the requisite tab on the squish pipe for secure mounting.

Looks like the tab was still there when the guy who imported the bike to Germany bought it in the US. I got these pictures from him. He changed a lot on this bike. Most probably to make a fast sell...
Seems like he cut it off for some reason.

And now? Any ideas how to secure the Squish? AFAIK welding on a frame is prohibited in Germany.

[George Greer]

On my panhead, (58FL).

I had a mis-mash of collected exhaust pipes and clamps, apparently everything was already tweaked on other uses.

I went to W&W cycle’s in Wuerzburg and got the entire kit from Gasbox, and other than just a slight tweak, it all fit perfectly and I am quite happy with the fit an quality of them.

Might be something to look into.

Now, for replacing the missing bracket,

I understand that welding on a frame in Germany, is only prohibited on the neck area.

Replacement bracket, If I had one that was missing, I would replace it and just not mention it to anyone

George

[nifty]

Something must be wrong with my Exhaust-Setup but I can't figure out what.

On my 62FLH the Muffler-Strut was mounted the wrong way, which came to my attention when I tried to mount the center stand.

After switching the muffler-strut from the inside to the outside I realised that the previous owner had cut the rearwards pipe of the y-pipe. That was probably because he used a later-style Repop muffler. With that being done it was impossible to attach the muffler because it would have contact with the mounting screws of the muffler-strut.

So I ordered a corrcet Muffler and a new y-pipe (both from Gasbox).

Now I was able to mount the muffler-strut and the center stand correctly while being able to attach the muffler to the y-pipe as well.

Problem is now with the connection between front of y-pipe and squish. Either I get the elbows, squish and Y-Pipe aligned or I get the muffler and Y-Pipe aligned. If I try to get the whole system aligned I either end up with y-pipe to squish out of limits or the front elbow not sitting correctly on the front cylinder outlet.

Maybe you can see from the pics if there is any error source I overlooked?

My 2c
Additional to all other comments:
OE muffler strut/support tube hangs down a little at rear, there is a subtle bend downwards in same area as the offset/dog-leg, your chrome repop support may not have this feature (or you may need to loosen frame bolts to let it droop a little more). With the correct hang-down/droop of support, the muffler is horizontal/parallel to lower frame tubes/rails, the 3-1/2" muffler P clamp hole aligns and so does the hole of front of muffler clamp. This drops your muffler at rear and gives clearance for axle removal and shock clearance to muffler when bike raised on your -59 center stand.
And will help reduce your kink at S pipe exit.

The downwards bend in support is not much, maybe 3/8inch. If not present in your support, I suggest you remove muffler, get a length of pipe, slip it over support and gently tweak rear of support downwards. There are also spacers, which you may need with longer bolts.
58102-49 SPACER 2 per 3-1/2inch muffler P clamp 58-78; you may also need a spacer and longer bolt at clamp at front of muffler. I don't know the dimensions of the OE spacers, just pack with washers to get everything aligned. This should address your problems at rear.

Nifty

[nifty]

Something must be wrong with my Exhaust-Setup but I can't figure out what.

On my 62FLH the Muffler-Strut was mounted the wrong way, which came to my attention when I tried to mount the center stand.

After switching the muffler-strut from the inside to the outside I realised that the previous owner had cut the rearwards pipe of the y-pipe. That was probably because he used a later-style Repop muffler. With that being done it was impossible to attach the muffler because it would have contact with the mounting screws of the muffler-strut.

So I ordered a corrcet Muffler and a new y-pipe (both from Gasbox).

Now I was able to mount the muffler-strut and the center stand correctly while being able to attach the muffler to the y-pipe as well.

Problem is now with the connection between front of y-pipe and squish. Either I get the elbows, squish and Y-Pipe aligned or I get the muffler and Y-Pipe aligned. If I try to get the whole system aligned I either end up with y-pipe to squish out of limits or the front elbow not sitting correctly on the front cylinder outlet.

Maybe you can see from the pics if there is any error source I overlooked?

My 2c
Additional to all other comments:
OE muffler strut/support tube hangs down a little at rear, there is a subtle bend downwards in same area as the offset/dog-leg, your chrome repop support may not have this feature (or you may need to loosen frame bolts to let it droop a little more). With the correct hang-down/droop of support, the muffler is horizontal/parallel to lower frame tubes/rails, the 3-1/2" muffler P clamp hole aligns and so does the hole of front of muffler clamp. This drops your muffler at rear and gives clearance for axle removal and shock clearance to muffler when bike raised on your -59 center stand.
And will help reduce your kink at S pipe exit.

The downwards bend in support is not much, maybe 3/8inch. If not present in your support, I suggest you remove muffler, get a length of pipe, slip it over support and gently tweak rear of support downwards. There are also spacers, which you may need with longer bolts.
58102-49 SPACER 2 per 3-1/2inch muffler P clamp 58-78; you may also need a spacer and longer bolt at clamp at front of muffler. I don't know the dimensions of the OE spacers, just pack with washers to get everything aligned. This should address your problems at rear.

Nifty

On the swing-arm frame bikes 58up you may also need a spacer, or a few washers, between the frame clamp and front exhaust pipe clamp, and frame clamp is usually higher up than rigid frame photos.
Nifty

[panheadrider1961]

front head pipe clamps 2 piece
65513-58 frame tube
65512-37a pipe clamp
90908-58 spacer as can be seen in pic Roodog added
4020W bolt 5/16 x 24 x 1 3/8 hex hd.
7041 lockwasher 5/16
7753 nut 5/16 x 24 x 1/4 x 1/2 hex
rear frame and muffler support
5924b spacer 2 pcs special spacer front 2 holes in bottom of frame you may have to move your stand dont see how you have it opted not to put this on mine use police ride off stand hope this helps