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Did you "have to" cut the body in order to get the core out? I would have thunk with some persuasion you could have possibly pressed out the core? Or no?
Another way that might work as a simpler alternative is after taking length measurements of the removed core assembly, and marking a straight line from end plate to end plate for re-assembly reference, take a hacksaw, cutter, what have you, and cut both ends of the existing perforated core about an inch or two inward from the end plates. Cut all the way through all inner tubes etc. Pitch the center portion entirely. Then using new stainless perforated stock, cut to required length and form an oval core that will fit tightly "over" the remaining portion of core on each end piece. Line up ends with a straight edge, also making sure the length is the same as originally, then tack weld the ends to the core, then finish weld. Tightly wrap fiberglass "blanket" (Cycle Gear and others carry this..mostly for dirtbikes, I think it was FMF brand..) around the core and reassemble.
I had "oem quiet" brushed alum. Termi's on my Laverda that I recently did this to, which by looking at the photos of the S3's, are pretty much the same internally, without the catalyst. You will get a nice deep sound from the large core silencer vs. a small volume core, which will have a sharper sound.
All you'd be doing essentially is removing the entire center core, and sliding a new core in place.
Pretty quick and clean...worth a try. :???:
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