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[LarryB]

Harbor Freight

[1abastarsmda]

I checked their website and couldn't find it there.  They have a store near me.  I thought I would stop in and see if they might have it.

[1abastarsmda]

I just called Harbor Freight and was told that they don't carry anything like that.

[1abastarsmda]

I ordered my Fullsac's and I have core bit coming, so I'm starting to prep the bike.  I have the right muffler off and I'm at the stage to take the endcap off.  Any suggestions on how to get that endcap off?  I'm not having any luck with getting it to break loose at all.  (YES, I have all 3 screws removed already).  Everything else is going as planned thus far.  I figured I should be able to have both mufflers ready to insert the new core in yet tonight...if I can figure out how to get the endcaps off.

Any help?

[guppytrash]

Just take your time with the end caps.  They are tight but you can get them loose by hand...use your open palm and give it a wack.  Rock it back and forth they will come off...I did not use any tools just your hands so you don't scratch.

[1abastarsmda]

I got the endcaps off.  I am very sorry that I ever decided to go forward with this project.  I have just spent over 4 hrs trying to grind out the welds in one muffler.  Neither one is done and I now have a hole in my muffler where I ground through it.  Luckily, the hole is going to be on the absolute bottom side of the muffler and should be past the end of where the new pipe will go.  I'm still not happy about this.  I'd like to know exactly what Dremel tool was used for this.  It is very difficult to get the tool down in there to work in the first place and I am grinding and grinding and not seeing the light of day. 

What Dremel attachment are you guys using?  I am trying with a 9901 Tungsten Carbide Cutter  http://www.lowes.com/lowes/lkn?action=productDetail&productId=73390-353-9901-03&lpage=none
What should I be using?  I am getting to the point where I'll be trying to sell some Fullsac's and a coring bit and spend a fortune on some aftermarket complete system.  If I sound frustrated, I am.  HELP!

Please, someone answer that isn't guessing.  I've noticed very quickly that just because people on here receive an e-mail about a posting, they think they have to give an answer.  You have only received an e-mail because you checked off "Notify me of replies".  That doesn't mean that you know the answer.

[LarryB]

Let me say that patience is a virtue; catch it if you can; seldom in a woman, never in a man.
When I did mine, I left the mufflers on the bike to grind the welds, made it more stable to work with. I had the bike up on the lift. Ez view into the muffler. With the dremel I used the small grinding wheel. got it at Home Depot. ground it till it looked close the tapped it backwards just a bit to release. weld broke away and then I ground away the remaining weld on the muffler to make removal of the baffle EZ.
As you grind the weld, use a back and forth motion with the Dremel. Don't let it stay in one spot or you'll.........never mind.
It took me under 2 hours to do both of mine. How mechanically inclined are you?

[1abastarsmda]

What grinding wheel did you use?  Do you know a part number or the exact "Dremel" part description? 

I followed the instructions step by step, but again the question mark in the original instructions became which particular dremel tool did he use that he was able to get in there and make it work.  They make a lot of different tools, as you know.  The one that I tried actually is shaped like a drill bit (if you checked the photo at the hyperlink I provided) and you cannot get it fit down in there parallel to the muffler shell, because it is not long enough and the bit holder will then hit the back end of the muffler.  You have to come at it from angles and then it acts more like a drill bit by only catching the weld with the tip of the bit.  In doing so, it jumps around on contact.

I'm quite capable of doing this type of job, however as is the case with many procedures, you can extend great efforts and never accomplish anything if you aren't using the correct tool.  If the welds were a 1/2" closer to the end of the pipe, I wouldn't be asking, as I'd have no problems getting it done with the tool I have here.  I tried several times to not put the bit the entire way into the dremel, but it loosens and falls out of the holder very quickly, so I'm obviously at that point where I am seeking help from those who have already been through this.  When I look at the photo that Jim provided for this step, it looks like his bit extends further out of the dremel than mine will, and I do not know how to rectify the situation.

Larry, let me say that I am obviously being very patient with the process...working 4 hours straight on one weld...but at some point you do have to get to a frustration point where you know that you are doing something wrong and you need to ask for some experienced assistance.  I really don't want to put any more holes in my muffler.  I think the one I did put in it already is in a really good spot, if there is such a thing.

Back to the original question...What specific dremel grinding wheel did you use?  Thanks!

[dartman]

HI, you have really expended a lot of effort, I used the same dremel bit that you purchased, I did before starting practice on an old muffler I had laying around, You need a lot of light, and you need to stay away from the muffler body I just let the bit follow the contour of the lip on the old baffle when it was flat I took the muffler and dropped the opposite end onto a piece of carpet on the floor the impact broke what was left of the remaining weld and moved the baffle inward about 1/16 of an inch I cleaned up what weld was left and removed the baffle, I really dont think it took an hour and I spent lot less time on the second muffler, It sounds like your working in the dark, its just like an operating room you cant have to much light. the bit your using is fine.

[1abastarsmda]

Well, I decided to go at it again this morning.  The first thing I did was drop it by the other end on some carpet in the garage.  What do you know?  It broke free.  Within minutes I had the guts out of that muffler.  I'm celebrating and taking a break now before I start on muffler #2.  I guess I had it last night and just needed a little encouragement today.  Once the welds were broken free, it came out real easy.  I assume I will be better at this for the 2nd one.

[dartman]

Good Deal, like most jobs the first time takes considerably longer, a dremel is a wonderful tool but at 35,000 rpms a slip can be costly.

[1abastarsmda]

Geez, I was hoping that noone would point out that Dremel tools are dangerous.  I was trying to forget that aspect of this.  Anyway, Dartman...do you play darts or what?

[dartman]

Yes, naturally I would excell at something that does not pay well, I do get a number of free shots on league night however,

[1abastarsmda]

I used to be on the Arachnid Pro List, but I just don't get out to play much anymore.  I still have a Scorpion dart machine in my basement that doesn't get turned on too much either.  I bought it from a local vendor that was going through some tough times.  I play steel and plastic, and I still get e-mails and phone calls for all the local events, but I just never show up anymore.  I don't think I want to find out just how out of practice I really am.  Well, back to the garage to move on to muffler #2.

[dartman]

I can relate, advanceing years tend to take the fun out of such activities, I always wanted a scorpion but a dozen years ago they were selling for a couple of grand so I settled for a decent wall mount, The pub where I played for years clo and I pretty much phased out, I substitute occasionally for a friend but without frequent practice ive lost my edge,advise how that second baffle turns out.