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[firefighter156]

Has anyone had to remove the baffle from the muffler housing of a D & D  2-1 Fat Cat after it has been driven for a while?  If yes, is it tough to get out?  Any suggestions or tricks to remove without messing up the housing? 
Thanks in advance for you feedback.

[KKM]

Remove the bolt/nut and spray inside with WD-40 (or your favorite Break Free type product).
Stand the body on one end for a while, then the other to let the juice run everywhere inside.

Now it got ugly, but it worked.

Find a 4X4, lay it on the driveway, take the pipe and pound it's tail end on the 4X4...repeat...repeat...repeat.
Be careful to hit the wood not the driveway!
Keep it straight up and down...repeat.

The baffel will slowly move out to where you can grab and pull it out.
Makes a lot of noise and I thought it would not work at first...repeat...

I installed the "quiet" baffel by reversing the process. Just be sure to line up the holes for the bolt and pound away.

Took 40 min but was not as hard as expected and did not bend the rear lip...

Kevin

[firefighter156]

Remove the bolt/nut and spray inside with WD-40 (or your favorite Break Free type product).
Stand the body on one end for a while, then the other to let the juice run everywhere inside.

Now it got ugly, but it worked.

Find a 4X4, lay it on the driveway, take the pipe and pound it's tail end on the 4X4...repeat...repeat...repeat.
Be careful to hit the wood not the driveway!
Keep it straight up and down...repeat.

The baffel will slowly move out to where you can grab and pull it out.
Makes a lot of noise and I thought it would not work at first...repeat...

I installed the "quiet" baffel by reversing the process. Just be sure to line up the holes for the bolt and pound away.

Took 40 min but was not as hard as expected and did not bend the rear lip...

Kevin

Sounds ugly!!  Thank you.

[tazmun]

That's what I did with mine. Now I'm thinking of adding more glass
to make it quite again. D&D said the glass should last 40k, NOT!

[cahdbiker]

localprez, I don't know if you could use my method on a D&D, but on other baffles I have removed I used a slide hammer while the muffler was still on the bike. I made a tip for the side hammer that would catch on the baffle and they came out easy. Did it when I pulled out my stock baffles on my 09. I had to drill a hole in them to get the hook on the end  of the slide hammer to have something to grab onto but it worked just fine. In this case the mufflers were off of the bike with the inlet standing on a piece of 2X6. Maybe this will work for someone.CAHDBIKER

[firefighter156]

Thanks for the tips

[aclass]

I tried all the tricks to remove mine but finally gave up for fear of ruining an expensive pipe.
Good luck

[dankwiz]

I did what KKM did though let it soak in WD40 for 24 hours before trying anything.  Came out remarkably easy.  Was all freaked out that I would ruin the pipe when I read these instructions.  I went from quiet to mid.  Quiet was too soft for me.

[MUFFMAN]

I let mine soak in diesel fuel for an hour or so. Came out with a few taps.