What year is your bike. When i did my 2013 SG the right and left baffles were definitely different from each other, in order to remove the right side you had to grind away the entire baffle at the weld or it wouldn't come out.
Nick, do you have any pictures of the right side removal? Videos that you reference don't really show detailed images of the work being done. That is my only hangup right now in pulling mine is the right side. I have 13 SG as well. I don't think I would remove the insulation and mesh, just the core.
Any suggestions would be appreciated. I plan on using a 3 inch hole saw due to the fact I don't have a small dremel or grinding wheel.
To see how it's actually done youtube "baffle removal 2013 street glide"
All it takes is an hours time, 3" hole saw and a die grinder. Total cost is about $30 bucks. I would recommend leaving in your cat for a little back pressure.
Shoot me a PM if you have any questions
I have attached a pic. Do i cut at A, B or C? None of the pictures or videos I have seen depict the exact cutting location very good.
And what did you do to get the right side out. Was it difficult to remove because of the cone at the header end?
We used a 3" hole saw which cut most of the baffle completely out. I think the inside dia of the pipe is about 3-1/4" so you have to use a die grinder and grind an 1/8" away all around to clean it up.
You will have to ask Nick but I believe he used a die grinder with a cutoff wheel and cut weld A to remove the baffels.
The worst part about this whole process is removing the fiberglass packing... that **** itches like a bitch and it floats around in the air and gets everywhere including your *** crack.
Use gloves and long sleeve shirt. It takes about 1 - 1-1/2 hours to complete. take your time
Yup. What he said^^^^ a grinder is the way to go, it's quick and easy, it took me about 30 minutes to do my first one. And yes, it sounds just as good as the cookie cutter slipons everyone is using, only difference is about 700 hundred dollars more in your pocket.