Bonneville America Forums Forums Technical Forums Exhaust Broken drill in exhaust

Decided to try and remove some baffles for some better sound and flow. The first one was tough as I stupidly tried to just beat the damn thing out. Then got smart cut off some of the tube sticking out with a dremel and was able to reach with a deep hole saw. 5 minutes done versus couple of hours and much swearing. Now got an aircraft drill about 1/2 dia. and drilled 3 hloes in each of the second baffles.
One problem. On last hole snapped off a piece of the drill behind the second baffle. Anyone see any problems with this being in there.

Might rattle some.... You might get lucky and poop it out on a ride Or you could take the pipe off and tip it up, see if you can get it to fall out.

Any chance you can get it with a telescoping magnet. If its not lodged somewhere you might be able to get it. Telescoping magnet

Put about 70 miles on today. No rattle. Sounds good. Also seems to cruise a lot better.

Can' get at it. Its behind the second baffle.

ballast

Thought they were called baffles? What is the baffle?

It is a baffle, he means the extra weight is ballast. Then again, you will be off balance so you need to break one off in the other pipe.

I meant the broken bit was ballast (joke) they are called baffles!! LOL

Joke also known as blather

Have to get used to your sense of blather. Although from what I have seen on the sight I kinda like it all.

I like it too...gotta have a sense of humor.

I've done three sets of America pipes. The end baffle is welded to the chrome pipe. I wiggle the tube around with my fingers, after about 4 wiggles it falls out and I hole saw the remaining baffle plate. The second baffle is tack welded to the perforated liner and will sometimes pop out just trying to drill holes in it. Never felt much performance improvement til third baffle was gone.

I just gutted a set of '07 America pipes, except for the &(*^#%# catalytic converter, man you talk about LOUD!! But the extra umph is noticeable. I used a 2 1/2 in hole saw for the first baffle, after cutting off the tapered cone and removing the center pipe. Then used a long piece of 1/2 inch iron pipe to wiggle the next little pipe out, and then used a 2 3/8 hole saw to remove next baffle. Then I drilled 2 (two) 1 1/4 inch holes in the next baffle using 2 12 inch bit extenders and a 1 1/4 inch hole saw. I also wiggled the little pipe out using the long iron pipe. The last baffle I used a 3/4 hole saw, drilling 2 holes side by side. A bit of work, but the results were well worth it.

Man! That broken bit is going to make your bike glow in the dark. You better get all those baffels out and get a freak on there today!

Second baffle out. All pieces of broken drill out,there was a couple of big chunks in there one inside the pipe in the third baffle. Explains different sound between pipes.Also AI removed,Freak is on, 160 on the mains so far. Still going to need some tweaking but I,m on my way. Big thanks to all the people here for the help.

I'm still not sure about fiddling with my Tors. I'm still sitting here thinking about just taking the 1st baffle out and some say by belting the sides of the baffle where it meets the pipe, it just breaks away. Others say it's best with a hole saw and drill bit extender to get at the baffle, and just cut a hole. I just don't want to do anything bad to my tors as I really like them but I'm greedy for more sound and hopefully poke. Dog or anyone else, can you re-affirm how to go about it

How about just drilling holes in that last baffle and see what it sounds like? Inobtrusive and very little work. If it's not enough, you can always connect the holes and completely remove the baffle.

Both methods work it's up to you really. I used an air chisel on several sets now with great results. But I have heard more than 1 person have problems with that method. My TORs are constructed differently than stock pipes,I don't think they would work well for a single baffle removal. Even at a full gutting I think they might be problematic. They have a perferated tube running all the way through the center of the baffles. I never gutted a set so I am not sure how many it goes through.

On the TOR's I am not sure about but on the stock pipes the first baffle is actually tack welded to the pipe. Definitely hole saw the first one. I was able to reach the first one with a deep hole saw from Ace Hardware and no extension. Wiggle and jiggle the tube sticking out until it is loose and get it out of the way. The 2nd and 3rd are tack welded to the mesh liner. You can beat those out real easy.

Nah, I think I'll put this one to bed for now at least. Until someone else can guarantee a simple method (fairly simple anyway I don't mind getting in there) which adds performance and a good note to boot with Tors, I won't be going there. Anyway, there's too many other things I want to do. Thanks anyway guys