drilling out baffle

cathoga · 11-12-2007, 08:51 PM

I have an 05 Nomad. I drilled out one of the baffles using the 2" hole saw method to cut the weld. I was off by a bit. The baffle came out just as planned. If you do this, do not push the baffle in any furthur. it will only make it more difficult to remove.There is now a gap between the inner and outer pipe as shown. It runs less than 1/2 way around inner pipe. Couple questions. One is this a huge problem? 2 Is there anyway to fix this? Any suggestions would be greatly appreciated. Sorry for the crappy photo. Haven't figured out close ups with camera yet.

blowndodge · 11-12-2007, 09:00 PM

Sorry about that cathoga. If you had been on board earlier you would have known that a 1 3/4 inch hole saw would have not cut into the inner pipe that shields the outside of the pipe from heat. I've heard some have used JB Weld and fixed it. If not, your chrome will dis-color and that butchered up heat shield will vibrate like crazy.

cathoga · 11-12-2007, 09:07 PM

I was afraid someone would say that. Actually the 2' hole saw , if centered exactly, probably would have worked. Will try the JB weld just to see. Thanks

rlfaubion · 11-12-2007, 09:24 PM

Sure sorry for your mishap man. I'd look for another set of stock pipes on Ebay or post around the various forums to buy. I suspect they'd be fairly cheap. Go for it again using the 1.75" hole saw as the Lord has spoken. Jokes aside I feel for ya. Good Luck!

cathoga · 11-12-2007, 09:31 PM

Good thing is I only did one. Good thing is I now know what size hole saw to use. Good thing is, lots of people get rid of their stock exhaust, so I probably can scare some up on E-bay over the winter:)

lw · 11-12-2007, 11:12 PM

Cathoga,
If you dont like the JBWeld idea, maybe you know a welder that can run a bead for you and put it back together?

11-12-2007, 08:51 PM	#1
cathoga Jr. Member Join Date: Sep 2007 Location: Great State of Maine Posts: 30	drilling out baffle I have an 05 Nomad. I drilled out one of the baffles using the 2" hole saw method to cut the weld. I was off by a bit. The baffle came out just as planned. If you do this, do not push the baffle in any furthur. it will only make it more difficult to remove.There is now a gap between the inner and outer pipe as shown. It runs less than 1/2 way around inner pipe. Couple questions. One is this a huge problem? 2 Is there anyway to fix this? Any suggestions would be greatly appreciated. Sorry for the crappy photo. Haven't figured out close ups with camera yet. Login or Register to Remove Ads
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11-12-2007, 09:00 PM	#2
blowndodge Sr. Contributor Join Date: Jul 2007 Location: Washington City, Utah Posts: 16,474	drilling out baffle Sorry about that cathoga. If you had been on board earlier you would have known that a 1 3/4 inch hole saw would have not cut into the inner pipe that shields the outside of the pipe from heat. I've heard some have used JB Weld and fixed it. If not, your chrome will dis-color and that butchered up heat shield will vibrate like crazy. __________________ I love my Victory Cross Country Tour 106. Smells like Victory! Ultra's are Limited There are two types of Harley riders. Those that trailer them and those that push them. The most Interesting Man in the World "Find the things in life you don't do well and don't do those things" Member # 0005
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11-12-2007, 09:07 PM	#3
cathoga Jr. Member Join Date: Sep 2007 Location: Great State of Maine Posts: 30	drilling out baffle I was afraid someone would say that. Actually the 2' hole saw , if centered exactly, probably would have worked. Will try the JB weld just to see. Thanks
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11-12-2007, 09:24 PM	#4
rlfaubion Sr. Member Join Date: Sep 2007 Location: Northern California Posts: 1,582	drilling out baffle Sure sorry for your mishap man. I'd look for another set of stock pipes on Ebay or post around the various forums to buy. I suspect they'd be fairly cheap. Go for it again using the 1.75" hole saw as the Lord has spoken. Jokes aside I feel for ya. Good Luck!
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11-12-2007, 09:31 PM	#5
cathoga Jr. Member Join Date: Sep 2007 Location: Great State of Maine Posts: 30	drilling out baffle Good thing is I only did one. Good thing is I now know what size hole saw to use. Good thing is, lots of people get rid of their stock exhaust, so I probably can scare some up on E-bay over the winter:) Login or Register to Remove Ads
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11-12-2007, 11:12 PM	#6
lw Sr. Member Join Date: Jun 2007 Location: Pasadena, Texas Posts: 2,117	drilling out baffle Cathoga, If you dont like the JBWeld idea, maybe you know a welder that can run a bead for you and put it back together?
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