05 Aero 750 hole saw mod

[Big B]

OK, so today I had some time so I ventured to Home Depot to get what I needed to modify my wife's stock exhaust. I measured the depth of the baffles and found the top to be about 6" in and the lower around 14". I already had 1 extension from when I did it before on my bike. But the extensions the store near me only has one in a 12" length so I had to buy another one. You will also need a long telescoping magnet. If you can find a drill extension that is 18" you will be set. You will also need a 1 1/8" by metal holes saw. I bought Milwaukee brand. As well as the drill guide for the hole saw. And of course a good reversible drill.
First, assemble the guide bit, hole saw and extension and place in the drill. I started w/ the top hole. There is a bit of a ridge inside the pipe that would not allow me to just slide everything in and hit the baffle, so I inserted the bit, and started cutting until I reached the baffle. Once at the baffle, I let the bit drill the pilot hole. Once I was through that, I then put force on the drill to start the hole saw cut. Once that was finished, I removed the drill and took the magnet and fished out the round piece of the baffle I just cut. Add the second extension and repeat for the lower baffle. At best it took about 15 minutes to do this. It is very simple to do and saved myself 4-500 bux on buying a set of pipes. It has a real nice throaty sound to it.

Here's some pics.






These are the pieces that come out of the baffles.


Here's a vid I made of it afterwards.

05 Aero 750 hole saw mod - YouTube

05 Aero 750 hole saw mod - YouTube

[-AJ]

it's definitely louder! sounds good! great job bud!

[johnphillips]

Alot cheaper than a set of pipes

[Lakota]

Sounds good, Bernie!

[Big B]

Thanks, amazing what drilling a couple baffles will do.

[old dad]

Sounds real good,,the pieces you took out and showed, these were the inner plates? past the outer/or end of the pipe baffles?

[falcon1234]

did you need to do anything to the carbs afterwards?

[camoman214]

Originally Posted by falcon1234

did you need to do anything to the carbs afterwards?

I didn't and it performs the same as it did before the mod.

[Badoshadow]

Thanks for the great description, pics and vid on this. I have read other threads on this, but i need the visuals, so this was great.
Hmmmmmmmmm, could be a project in my future.

Thank you for taking the time to show this.

[Big B]

Originally Posted by old dad

Sounds real good,,the pieces you took out and showed, these were the inner plates? past the outer/or end of the pipe baffles?

those were the ends of the baffles.

Originally Posted by falcon1234

did you need to do anything to the carbs afterwards?

nope. Just ride and enjoy the deep sound.

Originally Posted by Badoshadow

Thanks for the great description, pics and vid on this. I have read other threads on this, but i need the visuals, so this was great.
Hmmmmmmmmm, could be a project in my future.

Thank you for taking the time to show this.

no problem, you're very welcome.