Cobra baffle won't come out!

[Wayn-O]

I am removing the baffles from my Cobra pipes and having a hell of a time doing it.  It is an old set of pipes and they are caked in their pretty good with carbon buildup and soot.  I was able to get 5 of them out using a slide hammer and some PB Blaster.  Lots of soot came out with them.  The last one will not budge! I have banged and slammed on it backwards and forwards with the slide hammer and it has ended up mangling the one side of the baffle.  I am at my whits end!  A 5 minute job has turned into consuming a few evenings with no results.  Any suggestions?

And yes,  I have removed the set screw. 

[BonS]

No help here, but I feel your pain. I have a set of Viking pipes that I've tried to remove the baffles from to put in more packing and can't get them to budge more than a 1/4". Carbon. I'm definitely concerned that If I bang any harder I'll destroy them. For now they're just sitting in the corner waiting for a new approach.

I'm just thinking out loud but with baffles as small as the Cobra's, could you fabricate a "T" or "Y" bar for a drill and spin the baffles while gently pulling? This might knock off the carbon off the walls of the pipes and eventually clean out the bore and let you remove the baffle.

[sandy]

Try CLR or Lime away to loosen rust.

[Firefighter]

I would think if you were able to remove the five, then the last one will come out too. Soak it over night like you probably did and try again tomorrow. Is there any way to heat it or run the engine to heat it. Maybe a degreaser. Use patience and it will come out.

Not much help, I know.

[Prairie Dog]

If it is carbon holding things up, try oven cleaner.