This following steps are a short summary of how I made a custom, straight pipe muffler set for my 2022 Indian Scout Bobber Twenty. Without any real welding skills I used the stock headers. Simple, cheap, and I really like the sound. If you want some idea of how they rumble, check out the video above. If you have questions, let me know.
To start, I had two 12 inch long, 1 3/4 outer diameter aluminized steel pipes cut at a local exhaust repair shop. In addition, I had one end of each pipe expanded to fit over the 1 3/4 inch stock exhaust header. The length of the expanded pipe is 2 inches.
The new straight pipes might need some cleanup. I deburred both ends and sanded them. The pipes needed a light sanding on the weld line, too. After smoothing out the pipes I cleaned them with a denatured alcohol to remove any oil on the metal.
I painted the pipes and the clamps with Air Cure Cerakote Glacier Forge. The Air Cure Cerakote does require a small paint sprayer and air compressor. You can purchase spray cans of heat resistant paint. I gave them 3 coats of paint but still ended up with tiny scratches on the pipes when installing them. The secret to eliminating scratches is to keep the clamps wider than the pipe until you clamp them down. I know, but it didn't occur to me at first.
The baffles require a hole to be drilled in the pipes. Remember to leave enough room for the end caps if needed. My baffles sit about 3/4 of an inch inside the pipe. I installed Drag Specialties 1 3/4 inch Fiberglass Wrapped baffles. In my next video I am going to install Khrome Werks HP - Plus Drag pipe baffles and a more generic baffle to compare the sound and volume of each.