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Author Topic: anyone have a Baffle-ectomy how to  (Read 8791 times)

Offline buzz

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anyone have a Baffle-ectomy how to
« on: April 16, 2012, 07:43:14 PM »
Interested in drilling or punching out the baffles in my stock cans. I've done the drill out method on my 06 Vulcan 1600 classic, that was real fun. Three plates to drill through using hole saw. Two removed from outlet side the third had to be cut from inlet side meaning you had to pull the entire exhaust system and separate the mufflers from the pipes. It was a lot of work.
Is there a write up some where that details (step-by-step) either punch or drill process for the C-10?
Thanks.
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Offline snarf

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Re: anyone have a Baffle-ectomy how to
« Reply #1 on: April 16, 2012, 07:48:51 PM »
Quote from: buzz on April 16, 2012, 07:43:14 PM
Interested in drilling or punching out the baffles in my stock cans. I've done the drill out method on my 06 Vulcan 1600 classic, that was real fun. Three plates to drill through using hole saw. Two removed from outlet side the third had to be cut from inlet side meaning you had to pull the entire exhaust system and separate the mufflers from the pipes. It was a lot of work.
Is there a write up some where that details (step-by-step) either punch or drill process for the C-10?
Thanks.
Heck I'll do it, bring it on over.
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Offline snarf

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Re: anyone have a Baffle-ectomy how to
« Reply #2 on: April 17, 2012, 05:07:53 AM »
1 1/8" hole saw bit and a 12" extension.  The bit will fit exactly into the end of the exhaust. Slide it in till it stops pull the trigger untill it moves forward again; repeat opposite side.  All done
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Offline Outback_Jon

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Re: anyone have a Baffle-ectomy how to
« Reply #3 on: April 17, 2012, 07:16:02 AM »
Quote from: snarf on April 17, 2012, 05:07:53 AM
1 1/8" hole saw bit and a 12" extension.  The bit will fit exactly into the end of the exhaust. Slide it in till it stops pull the trigger untill it moves forward again; repeat opposite side.  All done
Yep.  That's the "How-To".

I used a step drill, because it was what I had.  Worked fine. 
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Offline snarf

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Re: anyone have a Baffle-ectomy how to
« Reply #4 on: April 17, 2012, 07:48:21 AM »
Quote from: Outback_Jon on April 17, 2012, 07:16:02 AM
Yep.  That's the "How-To".

I used a step drill, because it was what I had.  Worked fine.
Yes sir a step drill will work just fine.  One word of caution; when using the extension make sure that the bit is securely attached to the extension.  It really sucks to drill out the baffle for a friend only to find that when you pull back on the drill you find only an extension.  Lesson learned that day LOL.  All turned out ok.
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Offline roger dodger

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Re: anyone have a Baffle-ectomy how to
« Reply #5 on: April 17, 2012, 08:19:17 AM »
Originally invented by SISF, you do the deed (easily) w/ a 24" long rebar and a BFH. Have a friend hold the bike firmly w/ front brake. Then tap the pointed end of the rebar through the baffle. Repeat on the other side...no muss, no fuss, no crumbs to clean up.  ;)
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Offline jim snyder

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Re: anyone have a Baffle-ectomy how to
« Reply #6 on: April 17, 2012, 08:22:53 AM »
The drill makes a much neater and well defined hole. I used a 1-1/8" hole saw with extension, (the largest that will fit into the muffler)
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Offline snarf

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Re: anyone have a Baffle-ectomy how to
« Reply #7 on: April 17, 2012, 08:25:50 AM »
Quote from: roger dodger on April 17, 2012, 08:19:17 AM
Originally invented by SISF, you do the deed (easily) w/ a 24" long rebar and a BFH. Have a friend hold the bike firmly w/ front brake. Then tap the pointed end of the rebar through the baffle. Repeat on the other side...no muss, no fuss, no crumbs to clean up.  ;)
No offense to Steve, that method seemed so.......well crude. We have come along way since the stone hammer and granite chisel.  Power tools are your friend.  A couple of revs from the engine blows all the crumbs right out.
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Offline Stasch

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Re: anyone have a Baffle-ectomy how to
« Reply #8 on: April 17, 2012, 10:12:26 AM »
Originally invented by SISF, you do the deed (easily) w/ a 24" long rebar and a BFH. Have a friend hold the bike firmly w/ front brake. SAY:  "THIS MIGHT SMART A LITTLE BIT", Then tap the pointed end of the rebar through the baffle. Repeat on the other side...no muss, no fuss, no crumbs to clean up.

I fixed it for you!
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Offline jklhill

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Re: anyone have a Baffle-ectomy how to
« Reply #9 on: April 17, 2012, 02:07:43 PM »
A one inch chisel and a small sledge worked just fine here. Bada bing, bada boom, done.
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Offline DeansZG

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Re: anyone have a Baffle-ectomy how to
« Reply #10 on: April 17, 2012, 07:14:51 PM »
Yep, an extra long chisel & a BFH worked great here too!  Thought about the hole saw method, but noticed the hammer & chisel on the bench & that it would save me a trip to the hdw store for the correct sized hole saw...... 
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Offline buzz

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Re: anyone have a Baffle-ectomy how to
« Reply #11 on: April 17, 2012, 08:51:19 PM »
Let me get this right, if I punch a hole in the outlet side using whatever tool I have handy that is all it takes to open the exhaust?
Sounds way to simple, but it's a 12 year old bike.
Buzz
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Offline SteveJ.

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Re: anyone have a Baffle-ectomy how to
« Reply #12 on: April 17, 2012, 09:12:32 PM »
Quote from: buzz on April 17, 2012, 08:51:19 PM
Let me get this right, if I punch a hole in the outlet side using whatever tool I have handy that is all it takes to open the exhaust?
Sounds way to simple, but it's a 12 year old bike.
Buzz

Yup, just ram a pointy instrument up the out hole. Bang with a BFH. Repeat on other side. Congratulate yourself on a job well done. Celebrate with an appropriate adult beverage.

 :chugbeer:
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Offline west

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Re: anyone have a Baffle-ectomy how to
« Reply #13 on: April 17, 2012, 09:58:40 PM »
Does anybody have any sound clips of this?  I am interested in doing it, but I don't want to have the bike become obnoxiousness loud.  Had enough of that with my old bike which had open pipes with no baffles at all.  And it wasn't a Harley.   ;)
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Offline T Cro ®

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Re: anyone have a Baffle-ectomy how to
« Reply #14 on: April 18, 2012, 05:08:50 AM »
Quote from: west on April 17, 2012, 09:58:40 PM
Does anybody have any sound clips of this?  I am interested in doing it, but I don't want to have the bike become obnoxiousness loud.  Had enough of that with my old bike which had open pipes with no baffles at all.  And it wasn't a Harley.   ;)

Not a real big change in the sound level at all.... The muffler is still there as are the baffles so only some of the escaping sounds get to take the short cut out to the free world.
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Offline Outback_Jon

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Re: anyone have a Baffle-ectomy how to
« Reply #15 on: April 18, 2012, 06:41:22 AM »
Quote from: west on April 17, 2012, 09:58:40 PM
Does anybody have any sound clips of this?  I am interested in doing it, but I don't want to have the bike become obnoxiousness loud.  Had enough of that with my old bike which had open pipes with no baffles at all.  And it wasn't a Harley.   ;)
A bit more growl than stock, but not obnoxious.  I love it.  Wind noise is far more of a noticeable problem for me than exhaust noise.
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Offline roger dodger

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Re: anyone have a Baffle-ectomy how to
« Reply #16 on: April 18, 2012, 07:53:28 AM »
The sound is 'perfect' IMHO.

No one knows to look or listen @ idle, just a stock exhaust pipe. Then get on it above 4k and listen to the 'rip' as the exhaust opens up more space when you need it. Then back to stock for cruising thru small towns between rips.  ;) 
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Offline west

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Re: anyone have a Baffle-ectomy how to
« Reply #17 on: April 18, 2012, 10:41:07 AM »
All right, you guys just convinced me.  Time to get a hole saw. :D
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Offline AZBiker

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Re: anyone have a Baffle-ectomy how to
« Reply #18 on: April 20, 2012, 01:20:01 AM »
I'm working on shortening a pair of stock cans.

Had to put the project on hold until school is out and I can take them to my buddy's shop in Phoenix to use his chop saw so I can get a clean, straight cut on the can.

I can tell you one thing though--the 4 rivets on the front of the can just hold on the beauty rings, nothing more.
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Offline snarf

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Re: anyone have a Baffle-ectomy how to
« Reply #19 on: April 20, 2012, 05:13:39 AM »
Quote from: AZBiker on April 20, 2012, 01:20:01 AM
I'm working on shortening a pair of stock cans.

Had to put the project on hold until school is out and I can take them to my buddy's shop in Phoenix to use his chop saw so I can get a clean, straight cut on the can.

I can tell you one thing though--the 4 rivets on the front of the can just hold on the beauty rings, nothing more.
Yes Sir, Mama K did not want these cans falling apart while riding down the road
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