Bonneville America Forums Forums Technical Forums Accessories Baffle removal tool

Does anyone have a baffle removal tool for the TBA? I remember there were some floating around here awhile ago. That might be the way to go for me till winter then I can do a few mods at a time without worrying about the bike being down.- Fozzie

I took a 1 3/4 in. metal cutting hole saw, cut the cup in two equal parts, dobber welded a piece of 1 3/4 in. tubing (left over fence post) about 18 in. long. Welded the cutting end to one end of tubing and mandrel end to the other end of the tubing, Smoothed the dobber welds a little and drilled away. I wrapped a cardboard strip around the hole saw, old welder trick,to mark for a true cut and used a pipe cutter on the tubing. It's not perfect but works pretty well. I started drilling with a cordless but ended up with a 1/2 in. electric drill. I took all the baffels out of the short Triumph off road pipes and they sound great. I have spotted some baffels at a bike shop which will fit as soon as I get a ticket for loud pipes.
Also you have to remove the glass from the pipes. One side of the pipes had already blown out most of the glass but the other was full and firm. ****? Cost me about 15 bucks, But I welded it myself, sort of!

Could I borrow it?

The TBA stock pipes can also be de-baffled using only a 3 foot long, 1/2" drill bit (some hardware stores have these in stock). Just drill a few holes around the central pipe in each baffle and bend/yank/pry them out. Not as clean a hole but it will work if you can't find a proper hole saw setup as described above.

Send a message to mikesr
He's made about a half dozen baffle cutters and passed them around

Well that was relatively painless. I took a 2 1/8" hole saw and cut the rearmost baffle out of each pipe. Then with a 1/2" drill bit welded onto a 30" rod I drilled three holes in the other two baffles. The performance pickup was immediate! It seems like the motor works alot less and my cruising speed 65+ seems alot smoother. The sound is pretty good too! I'd like a little more bark and will probably go to drag pipes or shorty turn outs but that's a winter project. As for now...............We RIDE!!! Thanks to all for offering advice and info. Total cost of the project- $13.99 for the hole saw. I mooched everythign else. GOd bless the pack rat!-Bro Fozzie

Hey Bro!

I did the baffle Job as Todd suggested except when I went for the 4 1/2" holes I didn't get the first hole spaced up right and only had room for three. I really liked the sound, though it left me a little lean on the plugs, not real bad.

I ended up modifying the snorkle by putting four holes like in picture below. This made the most noticible differance in the engine wanting to go, even more than opening the baffles.

That improved the burn on the plugs even more. I just got back from the dealer to have him do a re-jet and check the bike out because I was a little nervous about the plugs. Well, he just shimed the needle jet and that improved the burn, cut back the popping and burn he said is just fine. (so now if something goes wrong in the motor it wasn't becasue of what I did!) It runs great too, all across the range.

Just remember, when you change something, it alters things in the combustion.

ed
Snorkle Mod

Found a bug, lost some top end. Runs good, but can't hit 110 any longer! Not that I need that...but it's nice to know I have it (had it)

ed