Fullsac Baffles

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Mar 1, 2021 | 08:07 PM

harley97

Thread Starter

Intermediate

Joined: Jul 2010

Posts: 45

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From: San Diego

Fullsac Baffles

I bought a set of 2.25" Fullsac baffles to put in my stock CVO Limited pipes. I have a couple questions.

1. What is the trick to getting the spot welds on the stock baffles off? I've been die grinding forever and it doesn't seem to be working very well. What bit should I be using or is there an easier way?

2. I bought the Techmat kit also. What are the advantages and disadvantages to installing it?

Mar 1, 2021 | 09:35 PM

Steve Cole

HD EFI Guru

Joined: Jan 2008

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Quote:

Originally Posted by harley97

The trick is to be careful. I like to grind around the weld some and get the baffle free from the weld. For me this makes it easier to see what I need to remove and what not and I do not care about the original baffle missing some extra material there. Once there I can just grind the the welds down smooth and pull the baffles out. I use some 1/2" carbide bits on a small air grinder. As for the techmat to me if makes the tone out of the exhaust note much nicer sounding and a little quieter.

Mar 2, 2021 | 08:23 AM

doctorjoe

Intermediate

Joined: May 2011

Posts: 42

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From: San Diego, CA

I, too, thought I was doing something wrong when taking out the stock baffles. Ya just gotta keep grinding. It’s takes longer than you’d think but the welds did pop out. Took me about an hour per baffle. It’s easy to think you’re just not doing it right...or perhaps YOUR’s were welded in with titanium. No, it just takes time and patience. worth it in the end.

Mar 2, 2021 | 09:21 AM

wethead103

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Joined: Jul 2015

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From: Ventura County, Ca.

Fullsac has a video on there website that shows how to remove the baffles. Good Luck

Mar 2, 2021 | 04:02 PM

harley97

Thread Starter

Intermediate

Joined: Jul 2010

Posts: 45

Likes: 12

From: San Diego

Feels like I'm just shining up the welds.

I watched their video, they make it look easy. Very misleading. This is taking forever.

Mar 2, 2021 | 05:37 PM

wethead103

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Joined: Jul 2015

Posts: 211

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From: Ventura County, Ca.

I used a carbide tapered bit. Took me about 20 minutes to do one muffler. Don’t be afraid to put a little pressure on the die grinder while your grinding the welds.