Join Date: Jan 2017
Location: Albuquerque, NM
Step #5, Pic. 5-6
Baffle cap and packing removal.
I opted to cut just behind the baffle cap to help ease peeling the body from the cap. Once the cap was free, I made a relief cut in the piece that was left on the baffle cap. This made peeling it off very easy. I used a portable band saw for all the cuts, but you could density do this with a hacksaw, grinder w/ cutting wheel.
Cut the cannister body to your pre-determined length. Again, I used a portable band saw, but you could do this by any other means that would provide a relatively straight cut. remove the packing and save it for later. Note: This process is very forgiving if you are not perfectly straight. The end cap can cover some oopsie-whoopsies.
Step #7 Pic. 7-8
The baffle is welded on the inlet side, so it is not easily removed for modification. The baffle diameter is 1.75" and it flares out to 2.125" to mate with the baffle cap. The end of the baffle tube left in the cannister needs to be flared out to match the 2.125" diameter, so I used a pair of small channel locks to SLOWLY flare out the end. Go slowly or you will deform and/or crack the baffle tube. I went around the circumference numerous times, before I was close to the 2.125".
Step #8, Pic. 9-10
Reinstall the packing around the baffle(Messy, very messy). Clean up the cut you made on the cannister body and baffle cap. Remove all the burrs and sharp edges or this will make reinserting the baffle cap difficult. Insert the baffle cap and slowly tap it down into the cannister body. I used a piece of wood and a hammer for this . The end cap should be flush with the cannister body when done. Check the the baffle tube is flared enough that none of the packing is going to get pushed out. I had to flare mine a little bit more at this point.
Step #9, Pic. 11-12
Reinstall the end cap and drill new holes in the body for the new rivets you will install. Use the same four holes that the original rivets were in. I believe I used 3/16" aluminum rivets for this. Match your drill bit size to the rivet you are using. Once drilled, install the rivets and pop each one.
Step #10, Pic 13-14
Re-install the heat shield(don't forget the rubber isolators) and then re-install the cannister on your bike. Enjoy the added sound on the cheap!