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[East Coast]

I ordered the Fullsac Stage 1 kit yesterday and have two questions.

1) I have a dremel and admit I dont use it often. Can anyone recommend a bit or is there a specific bit which will work best in grinding down the weld to remove the stock baffles.  

2) When installing the Fullsac baffles what is the general rule for the packing? Is best to put all the packing from the stock baffle back in, just some of it, none of it?  

Thanks in advance!!

[GregKhougaz]

EC, 

     You might want to read this thread if you have not already seen it for step by step, picture instructions:

         Installing Fullsac Baffles on 09 CVO Road Glide.

Your process should be identical.  In answer to your questions,  several of the dremel grinding bits will work.  You just need to use one that will get to the spot welds holding the stock cores in.  What to do with the packing is subjective so I would say there is no "general rule."  I used all of the stock packing and am very happy with the volume and tone of the exhaust.  (I also removed the cat.)  Hope this helps.  Good luck!

GK

[East Coast]

GK,
Thanks for the link, that's one thread I missed while looking around for topics on this.

    

[muddypaws]

I put the baffles in without the packing and it was too loud for my taste. I took the baffles out and installed all the packing from the stock baffles and really like the sound.

[cahdbiker]

East Coast, If you don't care about your stock baffles, cut some of the tip off before you start grinding the welds. It will make it much easier to get at the welds. I used a barrel shaped carbide bid and an air grinder. My dremel was taking forever.  In my earlier post I forgot to mention that after grinding the welds I drilled a hole in what was left of the tip that I shortened and then used a slide hammer with a hook to pull them out.I am sure I have mentioned this in another post so it may be a repeat.  CAHDBIKER

[HOGMIKE]

East Coast, If you don't care about your stock baffles, cut some of the tip off before you start grinding the welds. It will make it much easier to get at the welds. I used a barrel shaped carbide bid and an air grinder. My dremel was taking forever.CAHDBIKER

 

Makes fast work of the welds, just have to be careful and not use a heavy hand.

 

[East Coast]

Thanks guys for the tips!! Don't care about the stock baffles so cutting them to make life easier works for me!! I read the thread via the link posted by Greg above which was great. The kit is due to arrive on Monday. I'll be out of town for a few days next week and plan on getting to the install next weekend. I'll keep you posted.

Thanks again for the replies!! 

[mark]

I used the Dremel grinding stone (orange-brown in color...about as big around as a nickel) and the Dremel 9901 1/8" Tungsten Carbide Cutter.  Took about 30 min per muffler. You can go pretty fast until you get close to muffler body.  

How old is your bike...I did this a few months ago on my 2010 and I had to beat the crap out of the baffles to get them out.  The older the bike, the harder you'll have to bang.

If the baffles will not tap out, there are several ways to beat on them safely.  One member used the muffler hanger (at the exit end) and bolted it to his work bench so he could beat the baffle out.  I drove a wood dowel into the entry end of the muffler, then grabbed the muffler body, and slammed the dowel into my concrete driveway until the baffle came out.  Stock baffle will be unusable if you have to beat them out.

  

[TinSpinner]

A double cut solid carbide bit in an air powered die grinder will make short work of the welds but you need to be careful not to cut into the muffler casing too deep. A Dremel tool will get the job done if you have plenty of time. Be sure to wear safety glasses since the fines will be all over the place. I own a machine shop and do similar things with some frequency and am very anal with my employees about eye protection. It only takes one trip to the ER with a metal shaving in your eye to make a lasting impression.

[wideglidejoe]

I'll add my twist to this procedure.  I used my dremel, but I used the small diameter (~1") cut off wheel.  I felt I had better control without cutting thru the weld too fast and possibly into the outer case.  Once I had cut thru both welds, I used a 2" X 2" block of wood and tried to drive the baffle deeper into the case by 1/8" or so.  Then you can see if there is any weld mat'l left on the outer case that needs to be ground off.  Once that is done, I then gently drove a 1" wood dowel into the baffle from the inlet end of the case, and the baffle came out easily.

Best wishes on your work!

[East Coast]

All great helpful tips, thank you very much!

[cyco1450]

I know $$ is always a primary factor, but Fullsac will install the baffles for a mere $50 (plus ship).  the nice thing about that is if they damage your cans, they are responsible....and they do this job on a daily basis.  I've opted to go this route since I'd have to buy a Dremel etc and still run the risk of doing damage.

[CVODON]

Job is just way to easy to send back to Fullsac, IMHO. Took me about an hour and 3 Dremel bits, I also tapped the orig baffles into the can about 1/8th inch, then finished little burrs left by the grinding and the baffles literally fell out when I turned them over and tapped them once with a rubber hammer. Dremel would be cheaper than freight plus cost of shipping and you have to have bike down over a week total. That, at the time, was just not an option. Bike was new and needed to be ridden.

[dartman]

Job is just way to easy to send back to Fullsac, IMHO. Took me about an hour and 3 Dremel bits, I also tapped the orig baffles into the can about 1/8th inch, then finished little burrs left by the grinding and the baffles literally fell out when I turned them over and tapped them once with a rubber hammer. Dremel would be cheaper than freight plus cost of shipping and you have to have bike down over a week total. That, at the time, was just not an option. Bike was new and needed to be ridden.

X2 Dremel tool with cutters was $10.49 at Harbor Freight did a nice job

[East Coast]

I installed the kit on Saturday, knocked it out in about 4 hours with my brother taking our time. We used a die grinder and dremel for the removal of the stock baffles, no problem. Kudos to Fullsac on a really nice product! The improvement on there header pipe over the stock pipe where it sits into the exhaust ports is such an improvement!

I was able to get out this afternoon for a ride and put about 50 miles on the bike, it's runnning great!    I am very happy with the Fullsac install and would recommend it for those considering an exhaust and fuel management upgrade. No doubt for the money it's a really nice option and having the tuner for any future upgrades is a huge plus!! I bought the 2.0" baffles, they sound good, a nice deep tune, not very loud and certainly neighbor friendly. The heat from the cat is gone and the bike is running smooth with a noticable power increase.

thanks again for all the tips and advice!