I have a saw that has a similar diffuser and the hole diameter can be checked with bendable wire then do the math. Step drill up to a 1/4" hole to start and run it. The low speed jet will need to be adjusted.
Maybe I am butting in here on your thread but I find a step drill the best tool to make round holes in mufflers. I don`t see why you would have to rip your muffler open to accopmlish a simple port job on this saw.
Pioneerguy600
Because the restriction is inside in the form of the diffuser as discussed above
WOW, this sure got complicated.
I'd take said dremel, and slice the inner baffle tube from the inlet side of the muffler. The halves should seperate nicely then. Once it is apart you can remove everything from the inside and make two steel sleeves so the muff won't crush from the attachment nuts. You may find that no more outlet area is desired after this. I would try that first. If you still feel you need more, then you can add a port.
To do that though I'd still need to cut the outer surface to split the casing which seems too much effort on a brand new muffler considering I'll have to pay someone to weld it all back up.
Drilling an additional hole as Scott suggests would be easiest method but I'd be concerned exhaust gases would be competing to exit the two holes.
Welding the existing exit and drilling one larger one seems the most sensible option surely?
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