how to make a baffle for motorcycle exhaust

Creating a baffle for a motorcycle exhaust can be a straightforward DIY project if you want to modify your exhaust system to control noise or airflow. A baffle is typically a perforated tube or plate that reduces the noise and sometimes alters the exhaust flow. Here’s a general guide on how to make a basic motorcycle exhaust baffle:

Materials You’ll Need:

  1. Steel or aluminum tubing or plate
  2. Drill with various drill bit sizes
  3. Metal file or grinder
  4. Measuring tape
  5. Clamps
  6. Safety equipment (safety glasses, gloves, ear protection)
  7. Welding equipment (optional, if welding the baffle)


  1. Measure the Inside Diameter of Your Exhaust Pipe:
    • Use a measuring tape or caliper to determine the inside diameter of your motorcycle’s exhaust pipe where you plan to insert the baffle. This measurement will help you select the appropriate size of tubing or plate.
  2. Select and Cut the Baffle Material:
    • Choose a steel or aluminum tubing or plate that fits inside your exhaust pipe. The material should be heat-resistant and durable. Cut it to the desired length, considering the space available inside the pipe.
  3. Drill Holes in the Baffle:
    • Drill multiple holes through the length of the baffle using a drill with various drill bit sizes. These holes will allow exhaust gases to pass through while reducing noise and altering exhaust flow. Start with smaller holes and gradually increase their size until you achieve the desired sound and performance.
  4. File or Grind the Edges:
    • Smooth the edges of the holes with a metal file or grinder to remove any sharp burrs. This will help prevent airflow turbulence and reduce the risk of damage to the exhaust pipe.
  5. Test Fit the Baffle:
    • Insert the baffle into the exhaust pipe to ensure it fits snugly without any excessive play. You may need to clamp or secure it temporarily to prevent it from falling into the pipe.
  6. Weld the Baffle (Optional):
    • If you have welding skills and access to welding equipment, you can weld the baffle into the exhaust pipe for a permanent installation. Ensure it is positioned correctly before welding.
  7. Reassemble the Exhaust System:
    • After the baffle is securely in place, reassemble the exhaust system, including any brackets or mounts that were removed.
  8. Test Ride and Adjust:
    • Take your motorcycle for a test ride to evaluate the sound and performance of the modified exhaust. If necessary, you can further adjust the baffle size or hole configuration to achieve your desired results.
  9. Legal Considerations:
    • Be aware of local noise regulations when modifying your exhaust. Ensure that the noise level remains within legal limits to avoid potential fines or legal issues.

Modifying your motorcycle exhaust with a homemade baffle can be a cost-effective way to control noise and customize your bike’s sound. However, it’s essential to exercise caution and consider the impact on performance and emissions. If you’re not comfortable with these modifications or if you have specific performance goals, consult with a professional motorcycle mechanic or exhaust specialist for guidance.

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