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Discussion Starter · #1 ·
I have a Bonnie with Thruxton pipes.

I have read about people removing the rear of these pipes and cutting out the baffles (or rear baffle). Or, taking a 1 inch metal hole saw and cutting through the baffles with an extension on the drill.

Has anyone done this or have any knowledge of the best way to perform this?
 

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i just cut the baffle and pipe off just after the section narrows. bafflectomy is too hard and the result was boring.
i have a friend with a chrome cutting saw and we just took the muffler off and cut it in a few minutes. if you use other fast saws then it might leave a mark on the chrome.
 

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Yes, it can be done, I have done it and it's a pain. I used a dremel with allot of cut off disk, 3lb hammer, 18" 1/2 drive breaker bar (to beat the baffles out) and of course a 12 pack of your beer of preferance.

The trick is to cut the exit end of the cans with the dremel, I used an octagon cut, use a barrel roll attachment to round for the final product, large enough to beat the hell out of the baffles to break them loose. Then you can pull them out 1 by 1, as long as the large ones are folded enough.

The end results make a good sounding pipe, if you like loud, kinda of a cross between a flowmaster muffler and a glass pack. The idle sounds almost industrial, like the flowmaster, however, I have HD riders telling me my bike is loud!

Overall, very happy with the blood, sweat and frustration I endured for the finished product.

Difficulty scale of 1 - 10 = 10.99

Greg
 
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