Bonneville America Forums Forums Technical Forums Exhaust Baffle removal tool

Last year there was talk of a piece made for drilling out the baffles. As I understand, it was made by welding two steel bits together. The same type of bit you'd use for drilling a door to place a lockset through. The diameter was 1 and 3/4 inches, I think. If anyone knows where I can locate or borrow such a thing, I'd appreciate it.
Thanks
Ronnie

i believe mikesr was the maker of that tool, 1 1/2 hole saw cut in half and a piece of 1 1/2 tubing welded in ,lenth depending on how many baffles you want to remove. try a search in the archives, there should be more info there .
happy drilling

Hey Ronnie
I removed the last baffles in my Triumph SOR's using a 1¾" stell hole drill.
I got mine over the counter at a plumber's merchants.

Job took all of 5 minutes!

Have fun and make sure you remove one at time on each side (ie: in pairs) then try the bike for sound!
They're a bugger to put back if you need to!!

Do you recall the actual name of the plumbing shop where you got it or the part name or number? If I can get it here, I'll get one, but so far no one knows of anything available with the depth required.
Thanks

Ronnie-- You drilling a Speedy or America? If America, you only need to drill the end baffles. Easily reached with a good metal cutting hole saw. The baffles farther up the pipe knock out real easily, then use a long stout wire (I used 3/16" dia. rod) with a hook on the end to pull them out. Hook the loosened baffle, clamp vise-grip pliers on end of rod, and hit vise-grips with hammer. I took 2 out on each side.
Speedys I don't know, they have tapered pipes.

I picked up an extension at a local hardware/home improvement store that was about 24"-30" long. You mount the hole saw (or any drill bit) in one end and the other in the drill. It was a couple of years ago so sorry I don't remember where I got it from (try Home Depot, Harbor Freight). I'm not sure if this is much help or not.

I used mikesr's drill and it went really well taking 20 seconds each side. I started with the first baffle (end of exhaust) road for a while, then decided on the second in which I drilled 1/2" holes (I went with three because of poor placement with my first hole) if you go four, you get a great sound too. There is as much contrast in tone and volume between stock and when you remove the first baffle as there is between altering the second baffel. It is NOT too loud and sounds bueitiful!


Some have cleaned up the hole with a dremmel tool or file, I just shot black heat paint up there and you can't see it and (theoretically) it allows for a little restriction of gasses to give "back pressure".

That may only be in real terms good for my head, but half of what I do is for me, and may have no real affect on the world, but my perception is my reality!

I have clips on line if you want to hear what they sound like, both stock-first baffel and first - second.

eddy did you rejet after you drilled the pipes ,i know some guys here didnt but the more info the better ,im planning on doing the pipes in a few weeks cheers

Celt
I removed two of the three baffles in each of my stock pipes and now it runs lean(spark plug test).I am rejetting and installing TBS needles next week.To answer your question I would suggest checking your plugs after your post bafflectimy test ride,that will tell you if you have to rejet or not.
Have fun,
Mike

the hole saw is a good size to modify your airbox and filter too!

Hey Celt,

I made mod's to my air box which allowed more air in, then put a UNI filter in (less air from retricted air box= LEAN) I cut the bottom end off the snorkel, (more air) this helped a lot but still a little lean (spark plug test)

Took it to the dealer just because I was parnoid and in for some warrenty work on rotors, he shimmed the carbs and burning was slightly lean after that but that is normal they say and as long as he was saying it I was ok with it since it was then under his warrenty. And I mean they were on the very edge of brown so it was really close, no jets.

Here are some pics in my gallery. Exception is since the pic I cut the snorkle off just below the holes. Did this to maintain the direction of air intake maybe didn't have to, but has stock appearance on out side but better flow underneath.
Mods

eddy