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Discussion Starter #1
I've seen some questions on muffler rebuilds so I thought I'd share some observations.

This fall I thought my Arrow aluminum slip on was sounding a little too loud and raspy. It has 30k miles on it so I figured I'd rebuild it over the winter. I drilled out the outlet-end steel rivets with a 3/16 bit and bashed the end cap off with a rubber mallet.

Inside the packing looked fine, not loose or burned away at all. But I ordered some Helix Packing for $17 anyway to see if it made any difference.
http://www.bikebandit.com/helix-heavy-duty-muffler-packing-kit

This video was useful to me, although it's not an Arrow. https://www.youtube.com/watch?v=RNxKO18I-3I

I crammed the entire package into the muffler, applied Permatex muffler sealant to the end cap, and riveted it back together with 3/16 aluminum rivets. Piece of cake.

Before reinstalling it I sprayed it down with Liquid Wrench and was able to wipe away 30k miles of chain lube and road gunk pretty easily. At idle it's slightly quieter, but while riding it's pretty dramatic - exhaust note is lower and quieter for sure.
 

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I believe Cycle Gear repacks exhaust also.
 
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