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Discussion Starter #1 (Edited)
Fellow Vulcan Riders,

I need some advice from those with experience. I pulled my baffles out today. I wish I could say it was fun, it wasn't. It sure does sound good though.:D

Anyway, I bought the 3' hole saw to clean up the pipe, it doesn't cut the front plate off. It just kind of grinds down the outside. The directions from the delphi forum said you had to "rip it out".:eek: This sounds harder than it should be. My questions are as follows:

1st-Is 3" correct?

2d- If so, how far back do I grind down before I try to tear metal with my hands?

3d- Has anyone used a dremmel to cut the plate off from the inside out?

4th-Has anyone used a 2 3/4" to cut the face plate out?

Thanks for any help.
 

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1-yes but other sizes work
2- don't understand
3- haven't heard of anyone and the tiny dremel bits wouldn't last
4-I used a 2-3/4 since I already had it.
5-Cleaned up edges with grinding stone in a cordless drill
 

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Discussion Starter #3
1-yes but other sizes work
2- don't understand
3- haven't heard of anyone and the tiny dremel bits wouldn't last
4-I used a 2-3/4 since I already had it.
5-Cleaned up edges with grinding stone in a cordless drill
2.-Near the front of the face plate the metal appears to be thicker than further back. There is a lip of approximately 3/8 of an inch wide. I am wondering if I thin the metal with the 3" saw to that point, will the plate come off easier?

Thanks for the response. I am trying to avoid having to purchase another hole saw blade. This will be the 3d one. I bought a 3 1/4 first, then I realized that was too big for my purpose.:(
 

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I still have no idea what you're calling a face plate unless it's the part near the tip. I cleaned it up with a grinding stone in a drill. I believe all of the metal is the same thickness. If the baffle is out the only plate remaining is the one the baffles were welded to in front of cat converter. Mine is still in tact - haven't found (or really spent time) a good guide to stop the saw from walking.
 

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I know what you are saying. When you are cutting with the hole saw it looks as if it is basically grinding down the outside of the baffle housing (if you want to call it that). It is until a certain point. Just keep going and it will eventually cut through it and it will come off in your hole saw and you will be left with just the baffle pipe which you shove a broom stick in and work until the weld snaps. I cut on it for a while and thought the same thing and then pried on it and poked at it, etc. until it finally came out. With the bottom exhaust I just kept going with it until it came out in one piece in the hole saw. Wish I had known that on the first one, it would have saved me an hour, some cussing, and a couple cuts and bumps on my hands.
 

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Discussion Starter #7 (Edited)
I apologize for the inadequate description of my issue.

The baffles are out.

The plate I am refering to is the front of the baffle housing where 8 holes used to be drilled (prior to baffle removal). Now, the outer edge of the front baffle housing is still there and looks ate up like a soup sandwich.

The 3" hole saw does not cut the front of the housing off (I don't have a better term for it) to give a clean appearance. It is too big. It just eats up the outside of the housing. And yes, the metal near the front is thicker. (It may not be after it is successfully removed) I would take a pic and post it, but I am in a hotel room in Mississippi, somewhere between Ft Hood TX and Ft Bragg NC.

Thanks for trying to help. I'll give bradklines approach a go when I return home.
 
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