Since the V&H quiet baffles appear to be too quiet for me and because the aftermarket is letting us down with our softails I have decided to experiment and make my own baffles for my eliminator 300's. I have used some 1 3/4 O.D. to 1 5/8 I.D. exhaust pipe adaptors with multiple tweaks and I have fitted some tti-118. Unfortunatly I won't be able to start the engine for a couple of weeks due to other ongoing mods that I am doing.

 

That should work ,I experiment with depth on the inserts for sound and performance

 

Interesting, do you mind sharing a bit more on your findings?

 

I used Thunder Monster original baffle it's similar to your setup but the washer is slightly smaller and has a hole in it.
I was trying to achieve sound a bit quieter and found the deeper you placed it into the pipe it also helped to improve with back pressure but I also think it just depends on the style muffler or sound resinitor.
I think you're solit washer would be better . I'm forever chasing the perfect sound for not crazy loud but providing low end for the motor.
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Nice work! Sometimes its better to make it that buy it.