Join Date: Apr 2010
Location: Alexandria, Minnesota
Get a hole saw, 1" 3/4" i think, get a highspeed drill and drill/cut them out.
You are going to need vice grips and a dremel tool or air grinder, to grind down the weld spots on the inside.
What i did was cut the baffles out, then push them further inside a bit, so you can get access to the weld spots and grind them down. Then I had to grab the rim of the baffle and twist and pull, it took a good 15min of pulling and twisting to get one baffle out. It's not easy, by any means.
Use a little cutting/drilling oil for lubrication when using the hole saw to cut the baffles, it will smoke and get hot, try not to break any teeth on the hole saw.
Hope that helps.
I removed my baffles the same day I did a spline lube, was an all day thing.