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One other solution I am thinking of, and I have no idea if it would work, is to eliminate the chamber completely. I would remove the welded in baffle and insert a 1 3/4" piece of exhaust pipe (I could get that at any exhaust shop like Midas) then use that inner pipe for baffles.



Soren,
You are plodding on uncharted ground and therefore who knows what will help. But, I can tell you this - That 2-1/2" chamber does act like a megaphone in that it does amplify the sound. I beleive it may also contribute to additional popping - Hence, more noise. Here's how I come to my untrained conclusion - I have a set of gutted off-roads that are terribly loud and emit this crappy sound. I have a set of SM silencers in which an inner pipe was installed from the end restrictor/baffle to the open end in back. The sound is still nearly unbearably loud, but the tone is a tad better. I have actually considered playing with a bit of packing in this second, lined set to see if I could take some of the loudness away - But in any case, the set with the smaller inside area are the more bearable. Good luck.