Triumphrat

koifarm

When doing the bafflectomy, especially the grinding with the hole saw part, cover your bike and especially the tire/rim with a dropcloth. When you grind, small metal particles land everywhere and if they end up on your rims, spokes or any unpainted metal, they will rust within a days time.
Use a dust mask for the same reason. Sweep up under the mufflers after you are through or better yet, vacum the dust up.
I used a "remgrit" 1 1/4 inch carbide grinding tool which you can find at home depot or lowes. The cost on those is only about $7 and it works to grind rather than cut it's way through the pipe.
On the 07(mine) the baffle is shorter than the 06's.
I've enclosed pics to help you see the difference.
Bill

Attached Images

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	DCP_0003.JPG (71.5 KB, 99 views)

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Mods: snorkel removed, bafflectomy, jets out 3 turns, summer screen, cortec tank/saddlebags, Bella Corse Highlander bars,Modre peg lowering kit,Drag specialties mini tach, D9 bracket.

hoagie

I just bought a 07 america for my girlfriend yesterday and I rode it home for her neither one of us liked the sound to quiet. So this morning I gave it a baffelectomy here's how I did it . Take slip on off put in vise wrapped in towel as not to scratch it mark 4 and 5/8 inch back from center of back mount screw.Put a small mark I used a sharpie measure 2inches twards the front of pipe on opposite side again small mark. I used a 7 inch cut off wheel on a 4 and 1/2 inch angle grinder use the two marks for reference cut all around pipe the main thing is to keep your line straight. The whole end of pipe will come off then remove the hangar bracket grind the heads of the threaded inserts around the edges where they are crimped to the pipe. use a punch and tap them into the pipe the whole baffel assy. slides out. I left the very front baffel in by again using the cut off wheel and re inserting it leave the fiberglass on it so it won't rattle. I used 5/16 x3/4 stainless bolts wrapped a little electrical tape on the head so it would stay in the box end wrench put a flat washer on it reached in pipe bolt through hole flat washer again hangar flat washer than lock washer . Repeat for other hole don't need tape for that one don't completly tighten untill installed on bike.The bolts will keep the baffel from comming out Polish end with roloc disc on die grinder to get rid of any burrs repeat for other side and there you have a nice set of slash cut shorties that sound great I just orderd jets to for it just in caseThe whole process took 2 hours

macy517

Any tips for an 08 America with short slash cuts??

62rag

2008 Bonneville info(How I did mine): I wanted to keep the tips of the pipe, and the chrome intact. I used a 1-1/4" hole saw to cut thru the inner pipe. This left the baffle and inner stub pipe loose in the tailpipe. Instead of using the Dremel(hours and hours of work), I took the mufflers to a friend's exhaust shop(after removing the packing material) where he attached a slide hammer to the waste portions, and pulled them out cleanly. The baffle rings attached to the removed pipe section will fold back onto itself and pull right out of the pipe.

Some say to just slice the end off, but If you want the chrome to stay nice, and look stock, this is a good way to do it.

A couple of pics:

AFTER HOLE SAW


AFTER SLIDE HAMMER

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2008 Bonneville Black: FNG rider, bafflectomized, ride the crap out of it.

ramble59

Good stuff kdlutes, Nice sound, I might be doing this very soon!

AAustin

Wanted to add my thanks for posting this thread. Performed the bafflectomy on my '05 Bonnie this afternoon and am extremely pleased with the results. The 3/4" spade bit really did the trick. Nice throaty rumble from the pipes now.

I would add to this thread, you might want to consider chocking your wheels before you start banging and wrestling the baffle out of the pipe.