This is for Nyroc's mod . How many plates do you have to drill through?
what happens if there is air leaking form the cap sides where it is supposed to be welded? its only a couple of pin holes. Finally does this mod recquire jetting

 

there are three or four plates that you have to drill through. Be carefull not to go through the sides. The holes in the cap really are not that big of a deal, however if you are welding this thing back together, you mine as well weld the holes. Jetting will probably not be needed if you are leaving the end cap on.

 

well I made a huge mistake only whent through 2 plates i broke two bits inside, and on top of that my weld looks like crap

 

If I were you, I would take back of the cap and re drill it. You can by 18" drill bits at the hardware store that will get through them all. I put 8 holes in mine and welded on the end cap without boreing it out or anything. Whenk you weld it back on, weld the crap out of it so you can grind it down and it will paint up just fine. You will want to buy paint that resists high temps. I found a flat black spray paint that is used for barbeques and you can't even tell that I did anything to my pipe.

 

I wish I could have found an 18" long bit. All I could find was a 13" long one. I drilled through as many holes as I could reach. I drilled eight 1/2" holes.

 

My bit was only 12" long. Since the first baffle you drill through is recessed, the 12" one reached far enough as I had it clamped in the drill chuck as far out as possible, and as long as the drill chuck could go all the way to the first baffle (don't drill holes too close to the outside).

sicnj, you are not a welder? Some of my welds look like a million bux. The weld on my muffler is not really great since I refused to take it off. I used a mig which isn't great for upside down. If I took the muffler off I could have done better. I had no idea so many people would be looking at my muffler mod at the time that I did it.

 

I USED A MIG WELDER AS WELL. I REFUSED TO TAKE THE PLASTICS OFF. I THINK IF I CUT IT OFF AGAIN IM GOING TO HAVE AN EVEN TOUGHER TIME.

 

Becareful when welding on your quad ...the gas tank & battery... but also disconnect both battery cables... I disconected & removed the battery, when I was doing some frame gusseting, & mysteriously my K-BEK computer ( the other big electronic thing under the seat, not the CDI ), went out at the same time ???

 

Nyroc, I would have to say you are pretty famous for your "muffler mod". I copied it because it makes sense to spend $25 and save $225. I also "had" mine welded with the muffler on. I didnt want to break the gasket seals.

Mike, sounds like you had a bit of bad luck there.