So I got bored today and decided to try and take out the baffles on my stock pipes. I got a set of D&D on the way so just experimenting. I have a set of Thunder Torque Inserts that I never used and wanted to see what it sounded like. I read a lot about using 1 1/2 hole drill or just beating them out. So I took to it with a punch and hammer trying to know it out the exit of the muffler. The punch went right thru the disc that's about halfway in the muffler. Anyone got any suggestions on getting the rest of the material out. The muffler is tapered at the exit, I've read that theses aren't the easy to get out and it's proving right.

Update: went at the weld at the exit with a drill and a rasp bit and ground it out. After a lot of pounding with a mini sledge and steel rod it mostly came out.

 

I am thinking about punching out the diverter disk in my 05 1200C. How did your bike perform after punching? Did you end up drilling out the baffles? Thanks.

 

Sound bassy, I have done it for a friend just to sell his old Sportster lol.

 

This is a honda, but if the ends of your current mufflers look like the one in the video you can use a hole saw.

 

ive seen the drill method work ^

 

I assume when you open up flow on the exhaust you need to change out the intake and the jets??

 

All your newer bikes since around 2006 have fuel injection. No more jets to mess with, now it's fuel maps. If all you did was open up the stock baffle chances are you don't have to change anything. It's when you open up the air flow that a change is in order.