Quote Originally Posted by ojh View Post
I think i would have a mechanism where it 'pulled' the baffle into a seat. The seat could be a perminant piece of the header and it woyuld take the place of the very 1st ring of the baffle, it would have threaded inserts (similiar to used in wood) welded at about 120deg with allthread extending to near the end of the collector. Slide the baffle up into the collector working the allthread thru the remaining ring and start the motor end of the baffle into the seat, slide some larger o.d. sleeves over the allthread and run a nut down to the sleeve and pulling/pushing the baffle into the seat and clamping the whole mess in place without any hole to the outside. You could have the allthread just long enough to hold a trim ring to finish off the face of the collector.
I like your baffle, might have to copy it.
Not sure how that inner seat would be secured to the header, but I'm visualizing a "washer" with ID to allow slip fit of the pipe and three all threads pointing out? Even when assembling the header it would be a challenge to secure that unless I'm missing something, but I do like the idea of pulling the baffle into place. I think my method is going to be OK, but time will tell.

I took a bunch of step-by-step pics of the build process on this new baffle set and can post them later if anyone's interested?