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[stestrglde]

Just received my new fulsac 2.0 baffles in the mail and was wondering what would be the best tool to remove my old baffles without screwing up my pipes. Anybody do this themselves and have any good ideas.

[Raptor]

Just received my new fulsac 2.0 baffles in the mail and was wondering what would be the best tool to remove my old baffles without screwing up my pipes. Anybody do this themselves and have any good ideas.

One of the members from Illinois did a great step by step of this with his SERG.  Just search the forum or even google it, I believe Fulsac even uses it on their web site.

[wideglidejoe]

Dremel with a 1" cutoff wheel will cut thru the spot welds.  Just be careful that you don't cut thru the outer case.  Very easy job to change baffles.  I went with the 2" Fullsac baffles and I am very pleased.

Best wishes!

[LC110]

Here is the a step by step link for baffle install http://www.cvoharley.com/smf/index.php?topic=28086.0

[Alremc]

I used a dremel tool with both a wheel and a cone-shaped grinding stone. took longer but didn't want to mess up the pipe.

[cahdbiker]

stestrglde, If you don't care about the stock baffles first cut about an inch off the end of them. This will give you better access to the welds. Then after you have ground down the welds so the pipes will come out  drill another small hole in what is left on the exhaust tip an pull them out with a slide hammer with a hook on the end. This eliminates pounding them out with a piece of wood from the inlet end. Good luck CAHDBIKER

[stestrglde]

Thank you to all of your responses , Ill let you know as soon as I get them in and how they sound. I'm very curious
Thanks again to

[93-331-29psi]

do all fullsac cores look like this?  Where you can see the pipe inside the muffler?  I just ordered mine, but not so sure I like that look.  Can they be cut shorter?

[denis]

does anyone know if  they know someone that installs the fulsac baffles and remove the cat ant install the tts i live in chicago near ohera airport dont know much about the tts? i ride a 2012 cvo ultra

[HOGMIKE]

do all fullsac cores look like this?  Where you can see the pipe inside the muffler?  I just ordered mine, but not so sure I like that look.  Can they be cut shorter?

Yes (some are larger diameter)
Yes
Yes
 

[stestrglde]

Hogmike, I wish I could give you an answer, but after this weekend when I install them I will let you know.

[gg]

denis, I sent you some guidance yesterday using a PM. hopefully you got that information. I am the guy who lives in Libertyville, Illinois, about 30 miles north of Ohare. As for taking the cat out of the existing exhaust header, I took a different approach, that you may want to consider. I bought a new 2009 Harley exhaust header for the smaller engine that HD was selling in 2009. The exhaust pipe interior diameters are the same and it did not have a cat in it. I removed the 110 exhaust header and installed the other cat free HD header. Really quite easy to do if you have some mechanical ability and feel comfortable doing it. Good luck.

[stestrglde]

OK, just installed my new 2.0 fulsac baffles. Took about 2hours for everything, just have to go slow and be careful. The sound is pretty good, I was hoping for a bit more sound, maybe should have went with the 2.25 baffles but now that there installed I'm not changing it up. I did leave in the packing material and am not sure if that makes a difference. My next step is stage 1 kit and decat my head pipes just not sure which order.

[glens]

If it's more sound you're after, get rid of the cat.

[gg]

stestrgide, while removing the cat from your exhaust header will allow more sound, the largest benefit will be in creating a freer flowing system and a noticeable reduction in heat coming off the header, especially where the cat was located. If your bike is a 2009, i encourage you to look around for a 2009 exhaust header of one of the smaller HD engines. I think it was an 88 CI displacement. It is same diameter pipe as on the 110 engine without the cat, so you don't have to cut open and re-weld. Gives you a total stealth appearance. That is what I did and it fit perfectly and I have never had an issue. I used the 2.25 Fullsac baffles and TTS mastertune.