Only wrap the rope over the holes in the baffle. Look at my pictures in. first post.
That's my thought also. However SmokenJoe's video shows 3/8". In my attempts to insert the wrapped baffle you could see the black carbon on the rope right at the detent area and I did wrap it around the baffle slot's to keep OD to a minimum. I may try again. I heard there is a fireplace store locally that has 3/16". Of course it's a holiday so that's out for today. I'll keep at it since I like what I have and a little lower sound would be great. I'll update as I go.I know what you are saying Gunny. I'll bet the 3/8" rope is too big. There is a large indent in muffler near axle bolt head and most likely you a re hitting that. I think Joe used 1/4" rope and that may be the trick.
IT’S IN and I like it. I went for a ride and find the loudness pretty much the same, the “tiny” sound is gone and it is throatier. I’m glad SmokenJoe posted this thread. I quoted you ‘11’ because I thought that could be a possibility as all manufactured parts are not necessarily identical @ when, what lot and how old is the die. I also considered the rope diameter. One mfg’s 3/8” may not be the same as another and then there are always quality control standards. Enough said! If I were to do it again I would use ¼”. Now for the install: I wrapped the baffle as tight as possible to minimize OD. Once the front end of the baffle caught that stand off I had to tap it in with a piece of wood and small hammer. Then to align the screw holes, once the depth was okay, I inserted a small nail removal tool (@ deck nails) to the baffle slots and used a wrench to turn it. It is darn tight but all screws are in place. I hope I like it for the long run because I do not want to think about pulling it out. Sorry, no pic's but SmokenJoe did a great job with that. To recap ~ I like it.Hey Gunny- SmokenJoe's Outer muffler housing may not have as deep a dimple near the axle area as your's Possibly and that's what the problem is.
I used the Moose brand fiberglass packing in mine, but My indent is gone now that I shortened the slip-on.For those of you that have had this muffler apart. Do you think that using a fiberglass repacking material would fit back in? It sounds like that indent for the axle does not give much clearance. I would think that if it is possible to get the mat in there, it would do a better job of muffling than the rope alone.
I ended up sourcing some FMF 4 stroke packing - not too many places carry muffler packing around here... It looks similar to the pink wall insulation for homes. I wrapped pretty much the whole length of the baffle and got it back together.I used the Moose brand fiberglass packing in mine, but My indent is gone now that I shortened the slip-on.