Jack, Welcome to the Forum!

I do not know if it is possible to drill out a hole in the baffle and not damage the cat. I sort of doubt it.

Below is a video that you may find interesting in modifying the stock mufflers that have a catalytic converter inside the muffler.

 

that looks very interesting indeed. But seems to be very loud not? Where can i get these insert?

 

Yes, they can be loud...and to get the best performance, will be loud. You can use them in an aftermarket exhaust that still has a baffle in it, that will be a bit quieter, depending on the size of the baffle. But, the smaller the baffle, the more the engine is choked and won't deliver as much power to the rear tire.

Click HERE to see them.

The next best performing type of muffler, that is quite a bit quieter, is the Series E from Fuel Moto. But I don't think they are making them for Sportsters yet. It is based off the SuperTrapp design. I think there must be a company out there utilizing that tech for Sportsters.

 

I had a great conversation with the guys at Fuel Moto and will likely go with one of their products, PC V or maybe Power Vision. They also told me that exhaust alone is OK and I will need no map. This is great news as it allows me to make the changes in a logical progression limiting the cost at each step. I wish I could do everything at once but we all have budgets to keep. I also enjoy doing the wrenching on my toys, so not visiting the dealer is just icing on the cake!


I would recommend going with the power vision, costs more, but you can remove it after the tune is complete, and put it back on and retune faster once more mods are done (You WILL be making more) The Power commander works well, bus since it is a piggyback unit it has to stay mounted. Running the cables and finding a place to mount it is a pita. I bought the power commander V for my 07 custom and wound up buying the power vision because it such a more advanced unit.
Jack

 

I have a 2015 Iron 883 will the stock exhaust mod above with dk baffles run good or will there be loss of power etc? Anyone still running there bike like this? thanks for any help