De-baffleing the Beast!

lcash · 06-09-2015, 08:56 AM

So I drilled out the weld on my 2008 1600 Nomad (The Beast) baffles, they are loose to move up and down within the muffler but I cannot get them out. What are the best ways to get them out?

Lcash

Charles_T · 06-09-2015, 09:54 AM

What size hole saw did you use? I think I used an 1-3/4" when I did mine. Once it punched through, all I had to do was grip the baffle with a pair of pliers and wiggle them out. Now the wood piece I inserted in the middle as a drilling guide was another matter...that required some vice grips, as I had firmly wedged it in there from the drilling!

lcash · 06-09-2015, 10:07 AM

Quote:

Originally Posted by Charles_T

What size hole saw did you use? I think I used an 1-3/4" when I did mine. Once it punched through, all I had to do was grip the baffle with a pair of pliers and wiggle them out. Now the wood piece I inserted in the middle as a drilling guide was another matter...that required some vice grips, as I had firmly wedged it in there from the drilling!

I used the 1-3/4" I know I cut clean through since I can move the baffle laterally but it will not budge to come out!

tonik · 06-09-2015, 10:17 AM

I had that issue, on mine when I did it. Had to lock on with some vice grips and wiggle in a circle a lot. There is a pipe on the other end that fits into another pipe...you are fighting the build up of carbon that has them stuck together.

You may have to drill a second time with a smaller hole saw and take the outside ring off to create more wiggle room.

lcash · 06-09-2015, 10:19 AM

Quote:

Originally Posted by tonik

I had that issue, on mine when I did it. Had to lock on with some vice grips and wiggle in a circle a lot. There is a pipe on the other end that fits into another pipe...you are fighting the build up of carbon that has them stuck together.

You may have to drill a second time with a smaller hole saw and take the outside ring off to create more wiggle room.

Thanks, I may try that!

BigRat · 06-09-2015, 10:46 AM

Wiggle - twist - curse - repeat

They will eventually come out using that method.

redjay · 06-09-2015, 11:26 AM

A pair of vice grips used like a slide hammer. Remove the bolt that tightens the vice grips. Replace with a piece of threaded rod, add a weight and a couple of lock nuts on the threaded rod.

dshelly · 06-09-2015, 11:26 AM

Vise grip slide hammer.

tonik · 06-09-2015, 12:07 PM

Genius.

dabull · 06-09-2015, 02:11 PM

same issue when i had the Nomad...keep twisting and pulling and yanking...it WILL come out;)

cactusjack · 06-09-2015, 03:20 PM

7 years of carbon build up can make them tough to remove. Keep working them, they'll come out eventually. I did my 2007 when it was only about 6 months old and one of them was pretty hard to remove. I can only guess how difficult it might be after this many years.

**plumber63** · 06-09-2015, 06:45 PM

I used a inside pipe wrench to twist/turn them. Took me all of 10 minute to drill and remove them both, and it was two year old. If you could wedge something in it that sticks out so you can turn it might come right out.

lcash · 06-09-2015, 07:37 PM

Ok! Got her done! The right side (front cylinder) was a real pain! I had to use the "Vise Grip Slide Hammer" to get it out. The left side came right out with just the vise grip and a straight pull! I used some brake cleaner to get the WD-40 off then painted the inside with high temp black paint. I will wait till tomorrow and give it another coat before heading off to work. She purrs like a lion now!

Thanks to everyone with your suggestions! It was a big help!!!

Lcash

06-09-2015, 08:56 AM	#1
lcash Jr. Member Join Date: Nov 2014 Location: Houston, TX Posts: 43	De-baffleing the Beast! So I drilled out the weld on my 2008 1600 Nomad (The Beast) baffles, they are loose to move up and down within the muffler but I cannot get them out. What are the best ways to get them out? Lcash __________________ --------------------------------- 2008 1600 Nomad Diablo Black! Login or Register to Remove Ads
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06-09-2015, 09:54 AM	#2
Charles_T Jr. Member Join Date: Apr 2015 Location: Lafayette, LA Posts: 9	What size hole saw did you use? I think I used an 1-3/4" when I did mine. Once it punched through, all I had to do was grip the baffle with a pair of pliers and wiggle them out. Now the wood piece I inserted in the middle as a drilling guide was another matter...that required some vice grips, as I had firmly wedged it in there from the drilling! __________________ 2005 Blue/Silver Nomad VBA# 3084 Happiness is pushing your limits and watching them back down
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06-09-2015, 11:26 AM	#8
dshelly Sr. Member Join Date: Mar 2012 Location: Belgrade, MT Posts: 2,824	Vise grip slide hammer. __________________ Dave "(dshelly)" Shellenberger 2014 Harley Ultra Classic 2007 1600 Nomad (Black) Shellenberger Machine Belgrade, MT Various Bagger Member (Harley Chapter) VBA # 2395
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06-09-2015, 03:20 PM	#11
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	7 years of carbon build up can make them tough to remove. Keep working them, they'll come out eventually. I did my 2007 when it was only about 6 months old and one of them was pretty hard to remove. I can only guess how difficult it might be after this many years. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17
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06-09-2015, 06:45 PM	#12
plumber63 Join Date: Apr 2012 Location: NE Indiana Posts: 989	I used a inside pipe wrench to twist/turn them. Took me all of 10 minute to drill and remove them both, and it was two year old. If you could wedge something in it that sticks out so you can turn it might come right out. __________________ Troy Donat VBA #02401 2015 Voyager 2006 1600 Nomad black(sold) 2016 Salem, Antlers, 2017 Eureka Springs, Lake George, Antlers 2018 Custer NR, Antlers
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06-09-2015, 10:17 AM	#4
tonik Advanced Member Join Date: Dec 2009 Location: Cleveland Ohio Posts: 714	I had that issue, on mine when I did it. Had to lock on with some vice grips and wiggle in a circle a lot. There is a pipe on the other end that fits into another pipe...you are fighting the build up of carbon that has them stuck together. You may have to drill a second time with a smaller hole saw and take the outside ring off to create more wiggle room.
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06-09-2015, 10:46 AM	#6
BigRat Member Join Date: Nov 2012 Posts: 430	Wiggle - twist - curse - repeat They will eventually come out using that method.
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06-09-2015, 11:26 AM	#7
redjay Top Contributor Join Date: Feb 2008 Location: Ontario Posts: 6,942	A pair of vice grips used like a slide hammer. Remove the bolt that tightens the vice grips. Replace with a piece of threaded rod, add a weight and a couple of lock nuts on the threaded rod.
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06-09-2015, 12:07 PM	#9
tonik Advanced Member Join Date: Dec 2009 Location: Cleveland Ohio Posts: 714	Genius.
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06-09-2015, 02:11 PM	#10
dabull Sr. Member Join Date: Oct 2008 Location: Crestview, FL Posts: 2,409	same issue when i had the Nomad...keep twisting and pulling and yanking...it WILL come out;)
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06-09-2015, 07:37 PM	#13
lcash Jr. Member Join Date: Nov 2014 Location: Houston, TX Posts: 43	Ok! Got her done! The right side (front cylinder) was a real pain! I had to use the "Vise Grip Slide Hammer" to get it out. The left side came right out with just the vise grip and a straight pull! I used some brake cleaner to get the WD-40 off then painted the inside with high temp black paint. I will wait till tomorrow and give it another coat before heading off to work. She purrs like a lion now! Thanks to everyone with your suggestions! It was a big help!!! Lcash __________________ --------------------------------- 2008 1600 Nomad Diablo Black!
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