Go to Gadget's Nomad page and he will give easy step by step instructions on how to open your intake. It's a very inexpensive approach using K&N filters and Spectre chrome covers. It's called the Caddmann intake. I've done it on both sides cause I like the symmetry. But you can leave the left side as is if you prefer. Another option is to use Chuckster's intake for around $170 on one side. That uses a 7" round cover instead of the 9" stock dog bowls. Here's a link to Gadget's page and also a photo of my intakes. BTW Gadget's page is THE definitive Nomad modification source. Tons of useful info.OPening the air intake is something else I want to do. Is putting an K&N in there good enough? 2 dog bowls tho.... twice the cost...
No it won't damage your motor. I've run it that way for awhile without issue. In fact, I've run it by removing the V&H baffles all together and using ultimate baffles which are just short stubs at the end of the pipes. It gives enough back pressure so that I don't have popping deceleration. But I find the ultimate baffles too loud for my taste. Same with running the V&H baffles without the fiberglass wrap. I find the fiberglass adds a deeper sound than without them. But that's just me.Can anybody tell me if I remove the fibreglass wrap from my V&H mufflers if this will damage the motor in any way. I really like the sound but just a little concerned.
I did same on my 05 1600 nomad took about 30min. And sounds and runs great. Do it.Gee, that is really something....I had an 07 Nomad years ago and used a Milwaukee circular saw also along with a plug-in electric drill and recall that it took me about two hours to do the whole job on both pipes..I recall using a plug of wood (shaped like a cork in a thermos) in the original exhaust hole into which to center the drill. I also used WD40.
I tell you this just to say it worked for me, even though I hae no idea why you are having so much trouble..
It really resulted in a pleasant sound once I was done.
Hope you get a break through soon.