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[mark]

Got my Fullsac Stage I kit this week for 2010 SESG.  Ground down welds as good or better than shown in some photos on this site.  Took a 1 1/2" poplar dowel and tried to drive out baffle.  Dowel now stuck in muffler and baffle hasn't budged.  How hard can I hit the dowel w/o bending the lip (the end where the end cap goes) of the muffler?  I'm proping up the muffler on a block of wood with a thin layer of rubber on top of wood. 

I'm wondering since the bike is almost 2 yrs old, if the baffle has rusted to the muffler.  I also used penetrating lube spray on both ends of baffle...Any help appreciated.

[Diamondback]

 

The bending of the old baffles is no big issue.  For sure if the weld is not gone they will not budge.  That said, my two year old 09 was a "$%*&^(^" to get out.  Beat the living %(*^UR*& out of the right side.

It was scary but they eventually came out.  About thirty minutes of serious beating.

On my brand new 11 RG they came out with one good hit.  Must be the rust.

Good luck.

 

[hotroadking]

You might need a little more work on the welds my 11 took more than I thought. I used a large socket on long extension.


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[Mano]

HIT IT......I too spent too much time love tapping it. A couple of good hits will move it. I used (3) 1 foot) 1/2 drive extensions. Once the rust bead around the baffle breaks from the wall of the can it should start to move after that but you must hit it.

[mark]

what did u use to prop the muffler up off the floor...I'm using a couple blocks of wood.

[HOGMIKE]

Once you have the welds ground, let the muffler drop from about a foot on the OUTLET tube, forcing it in more, finish grinding the welds smooth on the inside of the housing (NOT THROUGH) just take your time and go easy.
That finished, stick a piece of pipe, or tree limb in the INLET side, and again drop it from about a foot or so, the core will push past the weld area and come out.
DON"T let your pipe/tree rest on the inlet flange, only on the inner baffle area.
I used an old 1" pipe, and rested it on the cat converter. Does YOUR'S have cats in the mufflers?
 
 

[mark]

Crisis averted...I turned the muffler upside down and slammed the dowel into the concrete...after beating it like &$(@)%  The baffle finally came out.  Thanks for the info guys.

[Diamondback]

 

Now for a sweet sweet sound.

 

[kb]

Try hitting it in the opposite direction a couple of times. it worked for me.

[cahdbiker]

Mark, congrats on getting those stubborn baffles out. Mine were very difficult and at the time my bike was only 3 or 4 months old. I didn't care about the stock baffles so I cut part of the tips off to so it was easier to grind the welds and after that I drilled a hole in the end of them and used a slide hammer to pull them out .Worked good. Enjoy your new sound.CAHDBIKER

[Dan_Lockwood]

I did mine while on my table lift.  I ground down the top and bottom welds with my air die grinder with a carbide round bit.  Then used a flat piece of UHMW plastic and a 3# deadblow and hit them inward to break the welds loose.  Then I finished grinding and remove the baffles with a pair of pliers.  Maybe I just got lucky.

Once out I dressed up the remaining welds on the mufflers and the Fullsac 2" baffles slid right in.  Took about an hour for the two baffles.