Has anyone direct experience of hole-sawing the baffle out of a 961 peashooter exhaust?

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I have watched a few youtube videos of people removing fixed baffles from silencers by using a metal hole saw to detach the central baffle from the exhaust and then pulling it out the back of the exhaust.

https://youtu.be/mhCETbWhf7A

Has anyone done this on a commando 961?

I am worried that it may leave something loose inside the exhaust that cannot be removed. I would really hate yet another rattle.

NB I wouldn't be asking the question if I could find a reasonably priced aftermarket exhaust that was 25% louder than the fabulous looking but silent original. I have to do something to mask the 961's engine clatter below 4000 RPM!

Thanks in advance.

Terry

Have you considered the fact…

Have you considered the fact that what you ask is illegal. If you want a noisy Norton, go for one which is exempt from current legislation by virtue of age.

I am not saying that the…

I am not saying that the noise level should exceed Norton pipes on sale legally today. I Just want my exhaust noise to match the engine’s mechanical noise. That cannot be illegal else the engine’s mechanical noise is already illegal.

Drilling out baffles

Yes can be done , check out this https://www.accessnorton.com/NortonCommando/drilling-out-961-oem-muffler-baffles.24329/

Thanks gents. Good pointers…

Thanks gents. Good pointers.

first attempt will be to temporarily replace the cat cross pipe with flexible exhaust pipe just to see what effect this has on sound and engine performance. My understanding is that a catalytic converter is not mandatory on UK motorcycles.

Norton do an after market…

Norton do an after market straight through exhaust system that does away with the cat, about a grand I think. I have one on mine.

I heard that exhaust in…

I heard that exhaust in Prime a factors in Redhill. My ears are still ringing. I would consider one one at say £350 but not a grand. Silly money.

New Norton decat pipe

the latest norton decat pipe which has a sturdier support Bracket On is £295 on its own but worth it ,u can of course take the cat material out of the cat ,well a fabricator/ meteal shop guy can, my local one offered,but in the end he repaired my existing decat pipe.

De-mystifying cat removal

i drilled out the cat web with absolute ease using an ordinary drill. The material is brittle but not very hard. I used a wood chisel to remove any hangers on. I got a lovely clean job with 20 minutes effort. What effect did it have? The engine runs about 20% better better below 3000 rpm. It still ain’t no Triumph but the splutter, puff, cough has gone at very low revs. No change to mid-range and top end. It is a very worthwhile update. Save yourself £300 on a Norton decat upgrade pipe.

Saints preserve us.!!

May Saints Columbanus and Saint Anthony forgive you, for I never can. :)

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