1K9
No'mo Rocket 4 me
Sounds good. How is it running? Have you taken off the intake plastic tubes? Do you have a CAT delete between the header and the slip ons?
Gutted my mufflers
- Thread starter vindex1963
- Start date
Sounds good. How is it running? Have you taken off the intake plastic tubes? Do you have a CAT delete between the header and the slip ons?
vindex1963
Turbocharged
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- Aug 3, 2019
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- 887
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- Payson Arizona
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- 2006 Rocket 3, 2015 Victory Cross Country
1K9
No'mo Rocket 4 me
Good deal. Can't wait to see the building details. Have a set of original pipes to play with.
vindex1963
Turbocharged
- Joined
- Aug 3, 2019
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- 887
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- Payson Arizona
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- 2006 Rocket 3, 2015 Victory Cross Country
vindex1963
Turbocharged
- Joined
- Aug 3, 2019
- Messages
- 887
- Location
- Payson Arizona
- Ride
- 2006 Rocket 3, 2015 Victory Cross Country
Steps I did to modify my OEM three pipe system.
1. Remove exhaust tips
2. I used my jig saw with a metal blade to make six even cuts starting in the middle hole to the inside lip of the muffler. DO NOT saw through
the outside of the muffler body.
3. The plate you see on the back of the muffler only covers up the welded nuts inside, after the six cuts it pretty much falls apart.
4. Now the fun starts, I used the chisel and hammer to extend the six cuts down enough so when the material is removed
the hole saw will clear.
5. I used a log needle nose plier to bend back and forth until each of the six sections break off.
6. Put a carbide burr or small carbide end mill in the Dremel and cut away at the two welds on each of the nuts welded inside the muffler
these nuts hold the exhaust tip on.
7. Use the chisel and break away each nut. Save them they will be used to re-install the exhaust tip and hold the baffle.
8. Now it's time to use the 2-3/8" hole saw. I only use the Milwaukee brand hole dozer. Secure the muffler and drill for safety so when it binds, and it will bind. I sat on the muffler and positioned the drill to spin towards the floor.
9. After you've broken through with the hole saw you'll need a big piece of pipe, I used my large chisel to beat the OEM baffle deeper inside
of the muffler body in order to break the welds inside the muffler. You will know when they break because suddenly it'll just drop.
10. I made my own slide hammer out of all thread, use whatever you have. Slide the slide hammer into the OEM baffle until it catches and slide
hammer it out, the OEM baffle will not give up without a fight.
11. The new baffle will be slightly loose so I used channel lock plyers to gently flair out the baffle until it slides in with some resistance. Flair only the side that goes in first not the side with the nut.
12. I used the screw that came with the baffles in a spot that you can't see to start then drilled out the holes using the OEM screws to put the
OEM exhaust tip back on.
13. Load a tune, the one I used is in my signature.
14. Enjoy the sound of your new pipes.
15. I added photos of my tools and the OEM baffles
1. Remove exhaust tips
2. I used my jig saw with a metal blade to make six even cuts starting in the middle hole to the inside lip of the muffler. DO NOT saw through
the outside of the muffler body.
3. The plate you see on the back of the muffler only covers up the welded nuts inside, after the six cuts it pretty much falls apart.
4. Now the fun starts, I used the chisel and hammer to extend the six cuts down enough so when the material is removed
the hole saw will clear.
5. I used a log needle nose plier to bend back and forth until each of the six sections break off.
6. Put a carbide burr or small carbide end mill in the Dremel and cut away at the two welds on each of the nuts welded inside the muffler
these nuts hold the exhaust tip on.
7. Use the chisel and break away each nut. Save them they will be used to re-install the exhaust tip and hold the baffle.
8. Now it's time to use the 2-3/8" hole saw. I only use the Milwaukee brand hole dozer. Secure the muffler and drill for safety so when it binds, and it will bind. I sat on the muffler and positioned the drill to spin towards the floor.
9. After you've broken through with the hole saw you'll need a big piece of pipe, I used my large chisel to beat the OEM baffle deeper inside
of the muffler body in order to break the welds inside the muffler. You will know when they break because suddenly it'll just drop.
10. I made my own slide hammer out of all thread, use whatever you have. Slide the slide hammer into the OEM baffle until it catches and slide
hammer it out, the OEM baffle will not give up without a fight.
11. The new baffle will be slightly loose so I used channel lock plyers to gently flair out the baffle until it slides in with some resistance. Flair only the side that goes in first not the side with the nut.
12. I used the screw that came with the baffles in a spot that you can't see to start then drilled out the holes using the OEM screws to put the
OEM exhaust tip back on.
13. Load a tune, the one I used is in my signature.
14. Enjoy the sound of your new pipes.
15. I added photos of my tools and the OEM baffles
Attachments
vindex1963
Turbocharged
- Joined
- Aug 3, 2019
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- 887
- Location
- Payson Arizona
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- 2006 Rocket 3, 2015 Victory Cross Country
Who still wants to mod their OEM mufflers after reading the steps above? 
By the time I did the 3rd muffler it took me 1/2 hour from start to finish. I think I have a total investment
of $150 in baffles, all thread and the hole saw. It's really not a bad job at all.
By the time I did the 3rd muffler it took me 1/2 hour from start to finish. I think I have a total investment
of $150 in baffles, all thread and the hole saw. It's really not a bad job at all.
Idaho Red Rocket 3
Living Legend
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- Nampa, Idaho USA
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- 2006 RIII Standard Bagger w/Fairing
I think you have a new cottage industry. We could mail our pipes to you for this modification.
vindex1963
Turbocharged
- Joined
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- 2006 Rocket 3, 2015 Victory Cross Country
Probably not me thinks. My back and hips and knees just can't take it. Getting old is irritating.
vindex1963
Turbocharged
- Joined
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- Messages
- 887
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- Payson Arizona
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- 2006 Rocket 3, 2015 Victory Cross Country
This thing just purrs.
chrisw
Bluebird
if you don't mind loosing the original look, there's is an easier way, just slash them half way up, Great write up, I might do that to a spare set I have.
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