Help on hole drill size please

[terbear]

They came today --- the complete set of stock exhaust for the Nomad.

After looking them over (very nice by the way) I thought I read somewhere to use a 1 3/4 " hole saw.

If I use this size I would be cutting right on top of the existing weld, I am thinkinking that would be difficult. However about a 2 1/4 " would put the cut near the edge of the chrome.

Is this OK ? , and am I right in assuming after the cut is made the center tailpipe will wiggle out??

Any advice from someone who has done the baffelectomy would be appreciated, as I plan on getting the hole saw tomorrow.

I rode the bike to work today for the first time, and it rained --go figure----

Terbear

Just did mine with a 2 inch. It cuts too big and you will end up with a gap. I had to fill gap with muffler putty before could paint.

[Yellow Jacket]

Go with the 1 3/4" hole saw. There is an inner pipe between the outside crome pipe and the small center pipe which is the end of the baffle. You don't want to cut into the inner pipe which is close to 2" in diameter. After the cut is complete the inner baffle will pull right out. You might need to grab it with vise grips and persuade it some but it will come out. I then used a grinder to grind the remaining edge down so that it was flush with the inner pipe.

Here's a drawing of the cross section of the stock muffler at this link:

http://home.insightbb.com/%7Ekpmh.005/N-Gut-Muffler.htm

Just did mine with a 2 inch. It cuts too big and you will end up with a gap. I had to fill gap with muffler putty before could paint.



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[scott2007nomad]

Did mine with 1 3/4", worked great.
Don't forget the dowel to get it started on center.

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[skimo]

I did 2 inch which does separate the outer liner from the inner exhaust tube.
http://www.knology.net/~tdq/100_1135.jpg

The 1 3/4 looks cleaner.

[caddman11]

Use 1-3/4" saw----makes great cut and will get through correctly.

[Bdog]

1 3/4" hole size with centering plugs then some grinding afterwards works great.http://i171.photobucket.com/albums/u319/blackiedog/nomad/100_0292.jpg

[nomad1600]

Drilling out that baffle is the easiest thing I have done on my bike. It took less that 2 minutes to drill each side out. Just use a big drill 1/2" or larger lots of torque. I used a 1 3/4" hole saw for metal, buy a good one. I then used a 1 1/8" dowel rod from Home Depot and I wrapped it one time over with masking tape, it fit right in nice and smooth. Next use a cutting oil instead of WD-40 it will help cut faster and cooler. Once you have drilled thru just grab the baffle with some vice grips and they pulled right out. I then used a 3/4" drum sander and ran it around the cut and it slicked everything right up. Paint it black and I swear you can't tell that anything has ever been removed.

The low rumble is so Sweeeeeet!!!!! Plus it is a lot cheaper than buying the aftermarket pipes.
Good luck