DIY Network

Install New Exhaust System From "Classic Rides" episode DCLR-108

In this eighth episode of nine, host Kevin Tetz and Dunk install a new exhaust system and color sand the body parts of the project '65 Electra Glide.

By the end of this eighth of nine episodes the project Harley-Davidson Electra Glide will look as good as it did when it rolled off the line in 1965!

In this first segment host Kevin Tetz and resident expert mechanic Bill "Dunk" Dunkleberger install the new exhaust system on the project bike. Fish tail mufflers also will be added that will extend out pass the back of the bike. Kevin and Dunk have decided to stay with a "true" duel exhaust system, so there will be one dedicated exhaust pipe for each cylinder -- and this will produce a unique sound!

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	Figure A
	Figure B
	Figure C

Getting Started

• In order to install the new exhaust pipes, the battery and voltage regulator (figure A) have to be moved so the rear pipe can fit through.

• Remove the brake pedal as well so you can install the front exhaust pipe.

• Remove the battery bracket and move the voltage regulator out of the way, and loosen and move the saddlebag guard out of the way. And with some maneuvering the rear exhaust pipe will go in.

• Hook the rear exhaust up to the rear cylinder head spigot (figure B).

  Note: This will be a metal-to-metal seal, which means once the motor runs and builds up a little carbon, it actually makes a tight fit. As parts heat up, they expand.

• Install the front pipe by slipping it in-between the gear case and the frame. Slip the new clamp over the shoulder of the header pipe and install that onto the front cylinder head spigot. (The header pipe simply slips into the front pipe.)

• Re-install the master cylinder and brake pedal, and it's always a good idea to use Threadlocker on important fasteners such as the brake lever nut.

• Re-install the battery bracket and voltage regulator, and slip a new clamp over the fish tail muffler -- and install that onto the connector pipe (figure C). A flat washer and a lock washer go onto the muffler bracket clamp -- and is hand-tightened.

• Install the front muffler camp bolt and make sure the connection is secured.

• Tighten all the clamps.

In the next segment Kevin and Dunk will finish installing the fish tail muffler on the other side of the project bike, and the fuel tanks will be color sanded and the painted parts of the bike will be polished.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Norton Abrasives

Sandpapers, cleaners, abrasives and bodywork supplies.
Website: www.nortonautomotive.com

Auto Body Color and Supply
Phone: 615-726-0361 (Nashville Store)

Corbin Saddles & Accessories
Website: www.corbin.com

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com