[Taurim]

My previous AEW muffler did not include a baffle so it was probably a different model. It was very loud, little difference in noise level when I started the bike without it !

It was this model :

[KC1961]

That looks very similar to mine. Mine has a 2" / 51mm perforated tube / baffle inside with sound deadening material wrapped around it. So your one doesn't have this? I can't imagine how loud that would be having heard mine.

[Taurim]

I think it was the same with the 51mm perforated tube. But for me it's almost straight through. The perforated tube is (too) big in diameter, not long enough and the sound deadening material volume is low.

What I call a baffle is more something like the tube on the right :



But the AEW does not come with that or a way to install a baffle easily.

The new generic muffler I bought corrects a lot of problems of the AEW :
- inox, a lot lighter
- longer, bigger diameter, smaller inner tube
- provided with a removable baffle

[KC1961]

I spent a while looking for a 51mm baffle that would be a straight-forward fit, screw onto the end of the perforated tube. I didn't find anything suitable which meant resorting to using silicone sealer to fit this:

[Taurim]

I did not find a correct baffle at the time either but I found my current muffler with  a more common 44mm baffle diameter and 520mm long.

The problem was that there was no exhaust kickup included but that's another story 

[KC1961]

Here's the quieter version of the AEW. I fitted 3 x M4 screws through the perforated tube to support the baffle as well as using silicone sealer. Although I'd like to have a neater / less bodgey type arrangement this will have to do until I'm able to come up with something better.

[Taurim]

With some carbon deposit it will be perfect

[Adrian II]

Is that a Bantam in the background to that photo?

A.

[KC1961]

Is that a Bantam in the background to that photo?

A.

1968 D14/4 supreme

[Adrian II]

I started all this nonsense on BSAs, but with a C15.

A.

[KC1961]

My mate has a 1959 C15 and I've been on it a few times. Strange how your opinion varies depending on the circumstances. When I jump off a modern bike onto it, it feels like a pile of junk, but if I get on it after riding my Bantam it feels like a luxurious powerhouse!

[Arschloch]

This is what I've found in my broken crank while repairing it.

[gizzo]

Nasty. Would it have kept running like that if you'd been less sympathetic? How many km to wear out like that, and what was the cause? I know you've mentioned it before but it's been a while. I hope you have time to document the repair. It's outside the scope of what most of us could do at home but it's interesting to see how it's done.

Cheers

[gizzo]

New suspension goodies from YSS

[Arschloch]

Nasty. Would it have kept running like that if you'd been less sympathetic? How many km to wear out like that, and what was the cause? I know you've mentioned it before but it's been a while. I hope you have time to document the repair. It's outside the scope of what most of us could do at home but it's interesting to see how it's done.

Cheers

It did run maybe 3km in that condition, enogh to take me home atleast. The failiour occured almost exactly at 20.000km and the bike was tuned to 37.5rwhp since 8.000km. At 19.000km i've dropped in however an forged piston that got it to 38rwhp and sized at the same time as the big end bearing failed. Therefore the most likely root cause is the piston which is why i'm back to stock piston.

The repair is straight forward, what is needed is a hydraulic press, a lathe and something to knock it into shape so it runs true. I don't have a press but a friend has. The more annoying part is the truing however it went really smoothly to my surprise.