Any exhaust specialists that can advise...?

[Sister Sledge]

There's a zillion things to try but what I'd advise is doing them with the least destructive first.
My initial suggestion (after trying packing) is on those inserts, on the ends which are right inside the cans, weld two small strips of plate to the sides. The strips extend further in a little - say 1 cm - and attach a large steel washer to the strips/lugs.
It would allow gas to be diverted a little around, some through the central hole and wouldn't cause too much initial damage. If it didn't work then all you do is grind the small strips of steel from the side of the pipe.
Crappy paint drawing:

https://farm8.staticflickr.com/7832/46460284595_b4cbe134a1.jpgtriplebaffles by Craig David, on Flickr
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CCM 404 DS

[recman]

Tbh, these particular baffles are fairly cheap, about £15 a pop iirc.
So ballsing them up isn't the end of the world.

[recman]

Ok, so I put a load of 5mm bolts in there and while I'm not entirely convinced it made a huge difference in terms of volume, it has definitely eliminated the slight crackly raspy sound and gives it more of a low, bassy tone.
Its much more like the sound I'd have liked to had in the first place.
Very interested to see what's next with Mr Hammers vision with these things.

[Mr Hammers]

[recman]

Oooh, they do look good.
Very interested to find out what they sound like.

[Sister Sledge]

What about weight? Is it similar to what was in?
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CCM 404 DS

[Mr Hammers]

recman: Not that it really comes across very well, but i'll video it when i finish the second one...and try the holes/baffle packing.

Sister Sledge: It is slightly heavier i think, but there's not a lot in it. Didn't think to weigh them, but i will next time!
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A Guide To Powerbands