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I did this on my '08 1200R. There is a solid baffle plate about 10" in. First I got a 1 1/4" wooden dowel, drilled a 3/8" hole down the center of the dowel on a drill press. Now you have a guide, to prevent drill drift, and keep the hole properly centered. I started out with a 3/8" hole. I used a magnetic telescoping tool to retrieve the metal shavings. I rode around a bit...still too quiet. I then drilled it out again to 1/2"...still too quiet. (By the way, you'll need some long bits to reach the baffle). I re-drilled it out again with a 3/4" bit. I was happy with this, plus there is still quite a bit of the baffle left to give some back pressure. It is louder than stock, with a percussive quality to it, but quieter than most aftermarket pipes. I prefer the look of the stock pipes myself, that's the reason behind this. I also changed out the air cleaner to a Performance Machine, so I got a dynotune via my SE supertuner. There is some significant vibration felt thru the pegs at around 3200 rpms, but I've lived with it for a long time, no big deal. This is my experience.
Drilled out dowel rod as a guide
Last edited by Buddy Shagmore; Dec 7, 2016 at 06:28 PM.
Not sure it would be a very good thing to be beating on your pipes while still on the bike... I wouldn't do it at least.
I think you'll get the best sound and performance from totally gutting the muffler and installing some Thunder Torque Inserts. Here is a brief video on how to go about it with mufflers that don't have the cats.
With your pipes you will not have to cut that much. Just enough to clear the welds and the baffles should pop right out.
I gutted the mufflers from my Roadster that have the catalytic converters and I'm going to install some Vance and Hines Baffles along with TTI's until I can order the 2 into 1 pipes I want.
These are the baffles I purchased off of another forum member. They are the originals from a set of Straight Shots. Im using the fiberglass baffle wrap that came out of the stock mufflers and installing them along with W158 TTI's as Kevin from DK suggested.
Last edited by Bowhunter8607; Dec 7, 2016 at 07:34 PM.
If it's any more than just drilling a couple holes 10" deep I probably won't do it. I would like it a bit louder and snappier sounding though. The stock pipes are pretty quiet.
Drilled mine to 3/4. Used a step bit and extension from HF. Didn't worry about centering it. Just stuck it in and drilled. Love the sound, louder but not to loud.
Used a 1 3/4 hole cutter saw to grind out the weld at the back of the baffle. Vice grip on back of baffle, a little twist, and pulled them out. Did not even remove mufflers from bike. 2008 Nightster/ Saltster now pulling 99 hp.
Drilled mine to 3/4. Used a step bit and extension from HF. Didn't worry about centering it. Just stuck it in and drilled. Love the sound, louder but not to loud.
why are step bits so damn expensive? $38.00 at home Depot! Jeez!
Last edited by Really Randy; Dec 11, 2016 at 03:11 PM.
Reason: Spelling
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Has anyone drilled out your exhaust baffles?
i have a stock pile of pipes i need gone.
