Sandy Koocanusa
Serious Thumper
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Don't blame me. I didn't vote for him.
Posts: 1878
Bigfork, MT
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To answer your original question, can the stock muffler be made louder... Yes it can. I removed the back plate from the muffler, which is held on by four rivets. Just drill those out. Then pull that plate out. It has a cage full of fiberglass attached to the back of it. You may have to wiggle the plate up and down, side to side a little to get it to come out.
Once it is out, you can gradually make things louder by A.) Removing the fiber glass from the little cage. B.) Using a long bit extender and a drill bit to drill holes in the baffle up front. C.) Drilling said holes and then leaving the back plate off entirely.
To reattach the plate, if so desired, you can drill appropriately sized holes where the rivets were and then use lag screws to fasten it in place. I carried mine around with me for awhile, putting it in whenever I thought I might bother someone by being too noisy. Then I figured "Joke 'em if they can't take a screw." The plate and little cage thingy are sitting on a shelf in the shed getting rusty now.
The bored out stock muffler doesn't sound as nifty as some of the after market ones out there, but I think it sounds a lot better than the tinny, quiet, unadulterated version I had before. Then again, I'm not all that picky. I've noticed no one wants to drive their car next to me in traffic anymore. I like that.
I posted pictures of some of this stuff awhile back in a thread entitled "This muffler is screwed!" Can't remember how long ago that was, but a search should turn it up.
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