my 2010 iron is wearing black screamin eagle mufflers. i was gonna pop the baffles out and tweak the holes a bit to gain a touch more sound.
after removing the muffler and the two baffle screws i found that no amount of beating and banging with a wood block would dislodge the baffle at all (in either direction).

am i to assume that when h-d coated the mufflers in black that they pretty muched painted the baffles in? has anyone found a sure-fire way to pop them out without ruining the finish?
as an alternative, is it safe to assume that drilling several 1/4" hole around the baffle outlet at the rear of the muffler would create the same effect?

thanks



disclaimer: i was only going to increase the size of the holes slightly. i understand backpressure/pressure waves are important to the engine. further, i know that a small increase in hole diameter increases area greatly.

 

This problem you are encountering happens with any of the new screaming eagle mufflers. It took me forever to get the baffles out of mine. I ended up taking some round stock putting it in through the inlet side of the mufflers and hammering the round stock until the baffle came out while my dad held the muffler in the air. Good luck

 

Rebar sharpend to a point on the grinder should do the trick.

 

is that for punching extra holes in the baffle near the outlet?
or for punching a hole in the baffle inside the inlet for a straight exhaust path?
or for pushing the entire baffle out?

 

I gave up with mine. Bought slip on's.

 

I had the chrome SE slip on's and yeah the baffles are hard as hell to get out, but I got them. What I did was take my 1/4" big drill bit and drill out every other hole to that size and then on the inlet side of the baffle (it looks like a ramp) I drilled two 1/4" holes. The bike did not feel like it lost any low end and did sound alot better, but was not crazy loud. I like open pipes so I ditched the baffles, but with the size of the slip on's they were just too big to be open so I got new pipes.

I took the mufflers off and used a floor jack handle and a hammer to pound them out and then a block of wood and hammer to get them back in.

 

Get yourself a wooden dowell about the same OD as your baffle ID. Squirt plenty of penetrating oil inside & work the dowell in circles. With a little patience, sweat & arm wear - they should wiggle loose...good luck!