My cousin purchased Thunder baffles for his 1999 FXDXT on ebay and we now see that they are about an 1/8 of an inch too narrow in diameter to replace his removable baffles in his Screaming eagle slip ons. Can we make a sleeve with exhaust pipe to make up the diameter difference and then install? Any other options?

Anyone else run into this? Sorry for crappy picture.

 

As long as the Thunder Monsters fit flush to the inside of the exhaust pipe, you should be fine. You don't want any air leaks, but it shouldn't be a big deal. There isn't too much pressure there anyway. I've had mine on for a few weeks and love em. I have heard of some people using a high temp sealant to secure theirs, but I'm not convinced that it will stand up to exhaust duty. A snug fit should be just fine.

Jake

 

I would think a sleeveshould work or you could wrap the baffles with somemuffler tape.
I installed the Khrome Werks drag pipes in my Samson II, Rip Saws. They were extra snug. I had to use a block of wood to tap them into place. There is no room to bolt the baffles into my pipes, because my down tips clamp onto the straight pipes right where the bolt would normally go. Now the clamp from the down tips also squeezes down on the aft end of the baffles. The baffles haven't moved since I put them in 1,200 miles ago.
Tom

 

sleeve em...mine are that way