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post #1 of 4 (permalink) Old 11-27-2012, 12:26 AM Thread Starter
Grand Prix 125
Main Motorcycle: Triumph Bonneville Americ
Join Date: Oct 2012
Location: Chesapeake, Va
Posts: 33

Has anyone drilled this type muffler out? I don't know what they came off of but are now on my 03 America. If you did how many and what size holes did you wind up with? And was it worth it?
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Bill H. PTC, USN Ret.
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post #2 of 4 (permalink) Old 11-27-2012, 11:43 AM
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Grand Prix 125
Main Motorcycle: Triumph Speedmaster 09
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Join Date: Jun 2009
Location: Cheshire UK
Posts: 26
Other Motorcycle: Triumph Speed Triple 1050
That looks like long standard exhaust that I de baffled.
There are 4 baffles in total. I removed 3 using a long large screwdriver and a hammer and a drill..its not easy.
The sound is great.. louder than TORs but not too much.
Definitely worth it.

Speedmaster 09,Short TORs,Remap,Norman Hyde Bellmouth,Solo seat,Lowered Hagon suspension,Bobbed fender,Sparto rear light
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post #3 of 4 (permalink) Old 11-27-2012, 11:42 PM Thread Starter
Grand Prix 125
Main Motorcycle: Triumph Bonneville Americ
Join Date: Oct 2012
Location: Chesapeake, Va
Posts: 33
Do you know of any video showing that being done on that type? I wouldn't mind trying it but it would be nice to know what is in there and how they are put in.

Bill H. PTC, USN Ret.
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post #4 of 4 (permalink) Old 11-28-2012, 03:16 AM
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Formula Extreme
Main Motorcycle: 2009 Triumph Speedmaster
Join Date: Mar 2010
Location: Fallbrook, No. San Diego County Calif.
Posts: 411
Other Motorcycle: Yamaha Seca Turbo
I have a 09 Speedmaster with the long slash cut mufflers ( stock ones)
First thing i did was remove the Catalytic converter which is about 3 " back from the clamp that holds it onto the header pipe. Using a 1" holesaw and some pliers to pull all the pieces out. Next used a Unibit (the tapered & stepped cutter) and cut the 3/4" pipe out of the baffle wall, ( the hole has to be about 13/16" to get the piece of baffle tube out that is left rolling around behind the wall).
I then drilled a 3/4" hole in the baffle wall plate.
I then removed the last baffle plate( at the slash cut end) and repeated the same sequences on each baffle wall.
I then drilled a 3/4" hole through each remaining baffle wall, the hole was about 2" to the side of one that had the welded tube in it. I did this to all of the baffle walls using a 14" extension on the unibit. At the slash cut end i welded a 2-1/2" reducer bushing to the mesh that is inside. There was a 1-1/2" pipe thread inside the bushing and i machined a 6" long Stainless Steel pipe nipple to about a .080" wall and polished the outside to a mirror finish. I screwed the 6" nipple into the bushing using loctite and then tack welded it for safety, It sounds throaty, quite loud, but not Harley loud and allows the bike to breathe better. You could leave the final baffle wall in place and have two holes in the plate instead of going to all the work i did of making nipples and welding them in. Des.
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