Muffler Modification for Newer Magnas (1993-2003)
by Robert Hilliard

If you want a deeper, throatier sound out of your newer Magna, but don't want to spend 300.00 or 400.00 dollars for new pipes, this is for you. All it takes is about an hour of your time, some rivets and some tools that you probably already have in the garage.

First we use an Awl or anything similar to knock out the center pin in the rivets holding the back plates to the muffler housing. This leaves the outer rivet still in place, you must remove it as well. To keep from damaging or enlarging the mounting tabs installed in the housing, we did not drill out the outer rivets. We instead used our Awl in a circular motion, using pretty good force to "whaler" out the remaining portion of the rivet. A pair of needle nose pliers and Wire Dykes help a lot here as well. Remember these rivets are just aluminum, and the mounting tabs are steel, use enough pressure to work through the aluminum.

Then once all rivets are removed, you will need 2 medium to large size vise grips. Placing one on the exhaust tube that protrudes from the muffler. Clamp the second pair perpendicular to the exhaust tube on the first pair of vise grips. The second pair is to give you something to hit with a hammer (you knew a hammer was needed on your expensive stock mufflers to perform this mod, didn’t you?, heheheh). Strike the second pair of vise grips with a good amount of force, may take a couple attempts to dislodge the end plate and baffle from the muffler.

This is a good time to take something like a small magnet to retrieve the rivet pieces that have fallen inside the muffler. Once the end plate has been removed take it to a vise, where you will clamp the baffle tube very tight. With a good hacksaw cut the baffle tube on the end plate side leaving a small portion of tube. Once you have cut the baffle off, use a file and wire brush to remove any burrs or flaking coatings.

It is now time to reinstall the end plate using 3/16" X 1/4" long rivets to attach the end plate back to the muffler. Clean thoroughly with solvent or alcohol etc, then mask things off and spray paint with flat black or semi-gloss black paint.

High temp paint is not needed but if you feel compelled to do so, go ahead.

One last tip, only remove one end plate at a time as to not get them mixed up, and they can be put back on the correct muffler.

Then when all is finished, fire up your beloved Magna and listen to the new music she makes, and realize that for only a couple of dollars in paint and rivets you have a sweet sounding exhaust system, that will not ring your bell while riding on long trips. The sound it creates is not as loud as say, Vance & Hines or Cobra pipes, but it'll give your Magna a throatier, slightly louder sound that you will definately notice for a fraction of the cost.





Note: In cutting the baffle away from the end piece, cut the pipe just an inch or two from the end piece as illustrated in the two pictures below.