fix for drilled baffles

[semo97]

I just went through a 97 tourer drilled exhaust first stage and cut pigs 1/2" from mufflers. Exhaust sounded like sh$$ even with bike running good.
the pigs are welded into a 7/8 ID baffle right at the outside end of the muffler. Cut them off with a small cut off wheel, you will end up with about 1/8" of 7/8 ID pipe sticking out. Look in there and see what size hole they drilled it with, mine were 1/2", does not give you much space around the drilled hole. I used some 7/8 ths fender washers. I drilled  a hole in the fender washer between the center hole and outside edge a bit larger then my sheet metal screw.  Put the screw in the hole you drilled and work it into the baffle to the back end and drill it through. that will plug it up I still had a small center hole in the fender washer but some of it was covered. 7/8 OD freeze plugs should work as well. I was hoping they were only drilled 5/16ths or 3/8ths but no such luck. Find some pipe with 7/8 ths. OD put it in the end about an inch and weld it place. I made my pigs 8" long.  It put the sound back to stock like the IS that my son has. It is time consuming, you need to pull the pipes off to work on them. Do not use anything large then 7/8 OD, I tried some 15/16ths in the freezer over night freeze plugs and they will not work.

[Dale_K]

I don't know how to fix the drilled out baffle but if there is a little bit of pig left sticking out you can extend it as much as you want with 3/4" copper plumbing fittings.  They fit perfectly.  I cut a slot in a 3/4" 45 deg ell and put a hose clamp over it to chinch it tight to what's left of the piggy.  Then I added a second 3/4" 45 deg. ell, which gets the pipe headed straight again.  You have to do this for all 3 piggies but it all fits inside the stock tip cover.  Extend it as much as you want past the cover.  It's pretty quiet.