I have a question that I hope someone else has tried or gave it some thought. On my 02 Sportsman 500HO the exhaust pipe going into the muffler is 1 3/4" in dia. and the pipe comeing out of the muffler is 1 1/4" dia. Now could any gain in power be accomplished be cutting a hole up to 1 3/4" and welding a Small pipe that size back in? I know why don't I just buy a performance muffler Right, I just tight. Plus I belive that power can be gained on little thoughts.

 

i have heard of people spreading the fins on the inlet of the muffler

 

I had the same thought once but I was thinking of plugging the outlet cutting it off and reweld the hole and then add a piece 1 3/4 straight out the back of the exhaust . But I ended up buying a pipe from Hpd .
Maybe I will try it I still have the stock one I feel the urge to tweak comin on

 

I cut a hole in the back of my stock muffler and welded a down pipe on it around a 2" pipe. I still have the the factory small one flowing to. Look at the pics.

 

When you did that did you have any more power or was it still the same?

 

I did notice a little but nothing big. Sounds good though.

 

looks pretty cheesey to me

 

Looks can be deceiving.