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[Bearcat1]

I am installing the Fulsac CVO baffles on my 2012 FLHXSE3.  I saw the instructions that were made from this site and a wooden dowel was used to knock the baffles out from the inlet end once the welds were ground out.  I measure exactly 1 3/4" as the diameter size needed for the dowel.  Can someone tell me what you used to accomplish this task or where to find the right size object?  I cannot locate anything that matches this diameter.  Thanks.

[muddypaws]

I just trimmed down a 2 x 4. After the welds are cut it takes very little force to get the baffles out.

[bokat96]

Trick is to knock the baffle into the pipe deeper...then grind down the little lip of the weld left they will come out much easier after this

[Bearcat1]

Trick is to knock the baffle into the pipe deeper...then grind down the little lip of the weld left they will come out much easier after this

Yes, evidently I havent cut through the welds enough yet because I tried hitting the baffle from the outlet end and it didn't budge.

[bokat96]

I used a piece of broken broom handle...around the edge of the outlet to break it loose about 8 inches long...i then used the longer part of the handle to knock them all the way out...however as you do this part you can't get the handle back out of the baffle easily...I broke it off and used the remaining for the other side.

[HOGMIKE]

Yes, evidently I havent cut through the welds enough yet because I tried hitting the baffle from the outlet end and it didn't budge.

 
Just go easy and take your time, they WILL pop loose and recess farther in the muffler, then you can finish smoothing out the 3 welds, and pop them out, piece of pipe, broom handle, whatever you have just set it in the inlet ON the baffle part (usually cat material) invert, and tap it out holding the muffler and handle against the floor.
If everything's clear, it'll come right out.......
HOLD on to the muffler so it don't get away from you!
Good luck.
 

[HOGMIKE]

PS:
Thanks Dood, had a minor meltdown here today!
 

[sjrcvo]

A piece of 3/4 inch pvc works also. My 2012 had a collar welded inside the inlet end which appeared to be part of the baffle, but wasn't. So make sure if yours has the collar that you are past that and it should drive out pretty easy. Like the others said driving the baffle back in a bit from the outlet end after you grind the welds down definately helped.

[stestrglde]

Bearcat1 I used a dremmel tool, 1 in circular and took my time approx 1/2 hr apiece. Once I thought I had the weld broke I used a 1x1 to beat in the baffle, continued to dremmel the weld and smooth it out until I could turn over the pipe and hit it out, Take your time it does work,  Good Luck

[mark]

After Dremel tooling the welds, I used a wood dowel about the circumference of a golf ball.  I drove the dowel into the muffler inlet until it became stuck in the baffle.  The ease of getting the baffle out will depend on how old your bike is.  I waited about a yr. after buying my bike to change the baffles and they were a bear to get out. After driving the dowel into the baffle, I held onto the muffler body, picked it up and slammed the dowel into the driveway.  After about 10 heavy slams, the rust bond between the baffle and the muffler body broke loose.

Also, my baffles were not usable after I drove them out.

[Bearcat1]

A piece of 3/4 inch pvc works also. My 2012 had a collar welded inside the inlet end which appeared to be part of the baffle, but wasn't. So make sure if yours has the collar that you are past that and it should drive out pretty easy. Like the others said driving the baffle back in a bit from the outlet end after you grind the welds down definately helped.

Got them out this evening guys.  Thanks for all the input.  But as mentioned in this post I was mistakening the mentioned collars as part of the stock baffle.  It's not.  I thought the edge end of this collar was what I had to beat on to get the baffles out.  I was like jeez, really?  So I was able to find a grinder wheel that worked better in my dremel than what I was using and the welds finally popped loose beating the baffles back in a bit then I beat them out with a piece of galvanized pipe.  Hope to fire it up tomorrow.  Then only thing I am not really hip on about the Fulsac baffles is how the ends go flush with the endcaps.  I wish they could have designed it to keep the small opening more hidden up in the endcap.  But I guess there's a reason for it.  If the sound is right I know I'll be happy though.

[D-N-D]

You will be happy with the results.

[jcraig147]

Thanks to everyone on this thread. I did mine and it was simple.  I am an electronics guy. If I can do it, anyone can!!

[Cvostu]

can always do what ai did,,,  send em to Steve and let him do it

[jcd520]

Tip-------------remove the welds with the mufflers on the bike(remove end caps first)---use air dremel with metal die (from your local tool truck man) . Be very careful and take your time. After grinding out the welds gently knock the baffle in about 1/8  inch---------there is slack--------then gently grind out any ridges and use some coarse emery cloth to smooth out any burrs that might hang on the baffle. Then fashion a rod (or use jerk hammer if you have one) with a hook on the end and simply stick it down in the baffle , turn it till you feel it hang , and jerk the old baffle out. I even installed my fulsac baffles with the mufflers on( you have to elevate the bike to drill the hole in the bottom of muffler for the bolt)--be sure to use a center punch for you bolt hole and start the drill very slowly til you are sure it won't slip out of the punch mark.
What I used for a jerk rod was just simply a piece of 1/4 inch rod with a small hook on one end and a long  "L" on the other. Use a hammer on the "L" end to knock the baffle out towards you, Just keep tapping til it comes out.