Hole Saw Exhaust Mod - 2011 Nomad

Topangajack · 10-24-2014, 02:24 PM

A lot has been said here about removing baffles. For what it's worth, this is my experience...

I cut out just the the rear baffle plates of my '11 Nomad using a 1 1/4" bi-metallic hole-saw on a 12" x 1/4" drill bit. I wrapped the hole saw in blue masking tape so it was centered. The job was super easy!

Total time to complete was about 10 minutes including the time it took to fish-out one of the cut disks that failed to come out with the hole-saw.

Not a huge difference in sound, but it is a little louder and deeper.

I like the changes.

-Jack

The Black Knight · 10-25-2014, 11:38 AM

Myklops · 10-25-2014, 11:48 PM

I went another route with my vaquero mufflers. Just did it tonight!

Instead of using a holesaw through the tips of the mufflers, I cut the weld on the base of the mufflers, right where the head pipe meets the canisters. A few taps with a hammer on the exit side of the mufflers, and the whole core came out the front! I removed the bricks of catalyst and punched the baffle plates out with an air hammer and a very long flat punch bit.

I then reinstalled the cores back into the cans, and welded the bases of the mufflers back up. I then masked and painted the welds with some silver hi-temp paint.

After reinstalling the mufflers, I fired it up.

What a difference! So much deeper than the stock exhaust, and it has a nice, pleasing sticatto when I throttle it. I expected an increase in flow over stock, and wasn't let down. The engine sounds so much happier now that it isn't being choked off!

Stands to reason; the stock mufflers have a baffle plate, two catalyst bricks, and then two more baffle plates that make the exhaust flow have to abruptly stop and change direction way too many times.

I couldn't be more pleased with the debaffle job I did. It gave me just the sound I was after, and saved me $400-plus dollars on a slip-on set or full exhaust.

Topangajack · 10-27-2014, 04:45 PM

Nice! that sounds like an elegant solution for removing the baffles. But I bet it took a wee bit more than 10 minutes ;)

Any problems with backfires?
-Jack

Myklops · 10-27-2014, 09:04 PM

It did haha. But I'm a bit of a perfectionist. I have noticed decel reigniting of fuel in the exhaust causing a popping sound, but backfiring through the intake, nary a bit. Up next is blocking the fresh air reed-valve setup with a marble ;). That should quell most of the decel popping.

Topangajack · 10-28-2014, 01:57 PM

"blocking the fresh air reed-valve setup with a marble"

I've heard this mentioned many times, but have to admit that I don't understand exactly what parts are involved.

When you do it, would you mind posting a how-to?
Thanks
-Jack

Myklops · 10-30-2014, 06:53 PM

I want to say someone has posted a walk through on this mod before, but when I do, I'll document my steps with photos and such.

houndawg · 11-26-2014, 09:27 AM

Is anybody getting any dis-coloring on your pipes from the mod ??

rick6375 · 11-27-2014, 11:11 PM

Have almost 23,000 sinse doing mine, no discoloring. Are you possibly running very lean?

houndawg · 11-28-2014, 08:06 AM

I haven't done it yet just thinking about it and didn't know if there was any that changes.

houndawg · 11-28-2014, 08:07 AM

haven't done it just asking

10-24-2014, 02:24 PM	#1
Topangajack Jr. Member Join Date: Feb 2014 Location: SoCal Posts: 15	Hole Saw Exhaust Mod - 2011 Nomad A lot has been said here about removing baffles. For what it's worth, this is my experience... I cut out just the the rear baffle plates of my '11 Nomad using a 1 1/4" bi-metallic hole-saw on a 12" x 1/4" drill bit. I wrapped the hole saw in blue masking tape so it was centered. The job was super easy! Total time to complete was about 10 minutes including the time it took to fish-out one of the cut disks that failed to come out with the hole-saw. Not a huge difference in sound, but it is a little louder and deeper. I like the changes. -Jack Login or Register to Remove Ads Last edited by Topangajack; 12-02-2015 at 05:41 PM.
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10-25-2014, 11:48 PM	#3
Myklops Jr. Member Join Date: Aug 2014 Location: Wisconsin Posts: 30	I went another route with my vaquero mufflers. Just did it tonight! Instead of using a holesaw through the tips of the mufflers, I cut the weld on the base of the mufflers, right where the head pipe meets the canisters. A few taps with a hammer on the exit side of the mufflers, and the whole core came out the front! I removed the bricks of catalyst and punched the baffle plates out with an air hammer and a very long flat punch bit. I then reinstalled the cores back into the cans, and welded the bases of the mufflers back up. I then masked and painted the welds with some silver hi-temp paint. After reinstalling the mufflers, I fired it up. What a difference! So much deeper than the stock exhaust, and it has a nice, pleasing sticatto when I throttle it. I expected an increase in flow over stock, and wasn't let down. The engine sounds so much happier now that it isn't being choked off! Stands to reason; the stock mufflers have a baffle plate, two catalyst bricks, and then two more baffle plates that make the exhaust flow have to abruptly stop and change direction way too many times. I couldn't be more pleased with the debaffle job I did. It gave me just the sound I was after, and saved me $400-plus dollars on a slip-on set or full exhaust. Last edited by Myklops; 10-25-2014 at 11:50 PM. Reason: Typo
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10-27-2014, 09:04 PM	#5
Myklops Jr. Member Join Date: Aug 2014 Location: Wisconsin Posts: 30	It did haha. But I'm a bit of a perfectionist. I have noticed decel reigniting of fuel in the exhaust causing a popping sound, but backfiring through the intake, nary a bit. Up next is blocking the fresh air reed-valve setup with a marble ;). That should quell most of the decel popping. Login or Register to Remove Ads
	0

11-27-2014, 11:11 PM	#9
rick6375 Member Join Date: Dec 2013 Location: New Castle, In. Posts: 365	Have almost 23,000 sinse doing mine, no discoloring. Are you possibly running very lean? __________________ 2005 800 Classic 2012 Voyager ABS
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10-25-2014, 11:38 AM	#2
The Black Knight Top Contributor Join Date: Nov 2013 Location: Italy Posts: 6,018
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10-27-2014, 04:45 PM	#4
Topangajack Jr. Member Join Date: Feb 2014 Location: SoCal Posts: 15	Nice! that sounds like an elegant solution for removing the baffles. But I bet it took a wee bit more than 10 minutes ;) Any problems with backfires? -Jack
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10-28-2014, 01:57 PM	#6
Topangajack Jr. Member Join Date: Feb 2014 Location: SoCal Posts: 15	"blocking the fresh air reed-valve setup with a marble" I've heard this mentioned many times, but have to admit that I don't understand exactly what parts are involved. When you do it, would you mind posting a how-to? Thanks -Jack
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10-30-2014, 06:53 PM	#7
Myklops Jr. Member Join Date: Aug 2014 Location: Wisconsin Posts: 30	I want to say someone has posted a walk through on this mod before, but when I do, I'll document my steps with photos and such.
	0

11-26-2014, 09:27 AM	#8
houndawg Member Join Date: Aug 2014 Location: Joplin, Mo Posts: 70	Is anybody getting any dis-coloring on your pipes from the mod ??
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11-28-2014, 08:06 AM	#10
houndawg Member Join Date: Aug 2014 Location: Joplin, Mo Posts: 70	I haven't done it yet just thinking about it and didn't know if there was any that changes.
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11-28-2014, 08:07 AM	#11
houndawg Member Join Date: Aug 2014 Location: Joplin, Mo Posts: 70	haven't done it just asking
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