I called Smartpartz to see if I was installing everything correctly and I was. I looked more closely at the baffles and noticed that the threaded hole in the new baffle is 7/16" from the collar whereas the hole in the exhaust is 5/16" and the new screw supplied by smartpartz is too long and bottoming out. It was the combination of the 1/8" gap and the screw being too that caused the baffle to be loose and bounce around.
I added a lock washer to the outside of the pipe but that prevented the heat shield from going back on.
Another call the smartpartz and the guy suggested I get shorter screws. Recommended 20x1/4 x 3/8. Couldn't find these so I cut down 1 inch screws.
Everything is finally installed and tight.
Here are some numbers as measured from about 2 feet away and 45 degree angle from pipe and the bike at low idle. Original pipes - 75-80 decibels. Big radius 87-95. Big radius with smartpartz 80-85.
Standing next to throttle and revving on the same order. 85-95, 95-107, 90-100
Ride wise I thought originals too quiet. Big radius was too loud. I could not listen to head phones (please no safety comments) and needing ear protection. A lot of popping on decel and was too loud to really accel fast and found myself cruising at 50-55 to limit noise. They sound great at idle, lots of throat and growl.
Big radius with smartpartz - louder than stock but I can still use headphones. Noticeably less decel popping. I am back to cruising at 65 comfortably. I accelerate quicker but I don't know if that is an increase due to better back pressure or that I am hitting it harder cause I don't feel guilty about walk g the neighbors.
My recommendation is if you want a little louder start with the extra baffles and install them before putting them on the bike. I would even go as far as to say leave the existing screw as is and drill a new hole 7/16 from the end of the pipe trim the supplied screw to 3/8 and install baffle. I would suspect this would give a tighter cleaner look and save a lot of slide hammering and dremel woes
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