baffle removel on O.E. pipes

[desertduckpv]

A newbee here wondering if anyone can give me some detailed guidance on what size whole saw is needed and do I have to drill at both ends of the muffler. working on o.e. mufflers on a FLHTI. yes I know it's simple just don't wanna screw up the mufflers. thanks for the help :wave:

[rotavr]

A newbee here wondering if anyone can give me some detailed guidance on what size whole saw is needed and do I have to drill at both ends of the muffler. working on o.e. mufflers on a FLHTI. yes I know it's simple just don't wanna screw up the mufflers. thanks for the help :wave:
FLHTI OE mufflers take a 1 1/8 inch hole saw attached to a 10 - 12" extension. Find a hole saw with a 1/4" pilot drill and you should have no trouble finding a drill extension to fit the pilot drill.
The baffle you are drilling / cutting out is approx 1/16" thick, so removal goes pretty quick. Each muffler contains two baffles, one accessable from inlet end, the other accessable from outlet end. The outlet end baffle can be drilled without removing the muffler, however make sure the pilot drill extends an inch or so beyond hole saw teeth to help "catch" the cut baffle. Otherwise remove the muffler and shake it til drilled / cut baffle falls out.
I have only removed the outlet baffle, as that permits the sound I appreciate, while still maintaining some back pressure for cyl scavenging. Good Luck! Abbydog1