|FOR THE DO-IT-YOURSELF DUCATI OWNER
After testing the mufflers for the first time there was an extreme popping upon
deceleration. So, until I can find a cure I suggest not tearing into your mufflers.
It looks as if I need to richen up my Power Commander. If you don't have any PC
or chip to put in, I suggest not performing this mod. I don't want you to do any
irreversible mods and have it sound like crap. Thanks.
|Drill and Bits, Hammer, Chisel, Safety Goggles,
Sawzall, Vice or Clamp
|The first step is to clamp the mufflers securely in either a vice (best
choice) or to a table using a c-clamp or something similar. Then,
take your drill and drill out the three rivets on the end and the two
rivets holding the bracket on the side.
|Then tap the rivets out with a straight punch. Be sure to wear your
safety goggles for all this impact work!
|Then you can attack the rear- take a chisel (not a wood chisel!) and
tap around the perimeter of the end cap to separate it from the
aluminum shell. You'll see that it'll come free with some effort.
|After it comes free, you can change angle and drive it completely
out. It'll just drop out once you pound it out enough.
|Then, find a block of wood or a stack of newspapers to pound the
end on. Grip the whole muffler like shown, and raise it up like a
caveman trying to bludgeon dinner.....
|...and come down hard and square. After a couple of these
bashings, the shell should separate from the body of the muffler,
and you can drag it out. The pic I took of what it likes like after
this didn't come out, but scroll down to the reassembly to see the
packing you will encounter.
|Now to get rid of the other half. Take the end cap that we whacked
out, and trace around it on the end of the body to get an idea of the
size of hole we're cutting out.
|I tried several options on the first muffler I did, and nothing
worked as good as this method. Plus, it's cheap. So, we first take
our center punch and tap all along the line we drew so that it has a
bunch of punch marks in it as a guide.
|Then we drill a hole big enough to get our chisel
started. That's right, chisel!
|And hack away! Make sure you're using a nice, sharp, durable
metal chisel and safety goggles. I tired a holesaw, a grinder, I tried
drilling all the way around, and I tried the reciprocating saw, but
they all were less than ideal. This metal is TOUGH, and the chisel
surprisingly ripped right through it more accurately than I thought.
|The reason why we tapped all the way around was because it gives
the chisel a sort of track to follow. The total process took only
about 5-10 minutes each.
|Once you're done, the two tubes we cut out just fall right
into your hands. We can ditch those now.
|And here we go. The hole is obviosuly not straight, but it
makes no difference to me since: a) it'll be covered by the
end cap, and b) it doesn't affect the operation or integrity
of the muffler at all. So, you can grind yours down but in
my opinion it's a waste of a bit.
|Then we can tap the perforated shell back into
semi-original condition from when we hacked it open.
|And, now for the wrapping. Again, I put this back in
because I like my neighbors. Just wrap it like you're
wrapping electrical tape- nice and tight and even. But, be
careful, this stuff is murder. Its little synthetic fibers
embed in your clothing and skin, and itch and scratch like
|Then you can slide your shell back on. If the packing is
tight enough it should go on very easily.
|When it gets to the end, you'll need to tap it back down. Take the
body and tap it hard on something soft, like a stack of
newspapers. I used a tree stump, but this picture is just for
illustrative purposes. You don't want to bash up the aluminum,
so don't whack it too hard.
|Then you can take the end cap and tap it back into place. I used a
rubber dead blow hammer. Make sure you get the cap right side
up so it lines up with the holes in the side and top correctly.
|You can cut off the fibers sticking out the end with a sharp knife.
|And here we are. I haven't yet riveted the ends because I don't
have a high quality riveter yet, but it's a simple step that I don't
need to explain. The difference is clear- I can't wait to hear how
|This page is in no way associated with Ducati.com, nor is it an entity of Ducati Motor Holding, S.p.A. All content, information, and views expressed
herein are those of myself and do not reflect those of Ducati or its affiliates. The "DUCATI" logo and "Circle D" are registered trademarks of Ducati Motor
Holding, S.p.A., all other content on this website is copyright 2006, Monster Man Productions.