Okay, so passed the EPA test today but the bike barely runs with the OEM baffle on it.

 

I have a spare pipe so want to remove the internals.  I used a hole saw on both ends to get started and then a steel bar and a 2kg hammer to belt the baffle out, BUT they are not budging; they move maybe 3-4 inches either way but thats all.

 

Is there something I'm missing here?

If you can move 3-4 inches I would think that you are nearly there, keep working it back and forth, use a little WD-40, not too much you dont want to saturate the fibre glass matting.

+1

Get the pipe hot before trying to wiggle it out - just don't use your fingers to grab hold of the baffle.

Right...all completed.  Even though I cut both ends with a 1.75" hole saw I still had to cut the muffler and pull the baffles out in the end (you can see why in the attached pics)

Once I inspected the internals; it was fairly obvious that they would never have come out anyway as the two large rings are welded on very well.  Once I cut the end off then everything just fell out.  A few minutes with the TIG torch and the end looked good as new (ish).  I painted the weld in silver zinc and once the chrome cover is on you cannot see it at all!

Kuddoz Tussuck,

Harley must have changed the design of the basic mufflers, the last time I did a set it was a case of simply hole sawing the end and then a bit of elbow grease. By the way, you can purchase a chrome spray in a can, don't know if it is heat resistant though.

I wasn't expecting the step down pipes.

I was completely baffled by this one.

We should have sawed it coming though.