HS is going the right direction with this, I believe. Going back to my Hardley days, the baffles were removed completely and replaced with a 1/4" bolt to provide sufficient backpressure- they still ran like crap, but boy were they load!!! :goofy:
Ok, I digress, if you completely block off the end, you will have too much back- pressure and the bike will not run correctly. If you drill a whole in the end, you may improve this, but you may also induce a whistling noise that is annoying at best. What I have seen done that appears to work well is to crimp the leading edge of the baffle. This splits the exhaust airflow, some will go through the baffle end, some is redirected to the outside surface where it will enter the perforated section of the baffle.
To do this, heat the baffle with the torch and bend the leading edge in to form more of a cone shape. Its kind of hard to explain without a pic, so think about it like this. Imagine what would happen if you squeezed the end of the baffle equally around its circumfrence (provided you were strong enough). It would taper down to a cone, which is what you want.
Oh, I forgot the most important thing- AWESOME MOD!!! :beer: