Repacking Muffler-cutting Required

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I'm not talking about repacking the silencer which is fairly simple, but repacking the muffler in between the header and silencer. I first torched it which didn't make much difference, so my next step was cutting four holes in the muffler. On my 95 Fantic Section I figured it wouldn't be so hard since the sides are flat. I used a Dremel cutting bit and cut two oval holes on each side about 1 inch by 1 1/2 inch. The muffler is made the same way as the silencer with a perforated tube with fiberglass packing between it and the shell. Then I used an old brake cable frayed at the ends and loosened all the oil soaked fiberglass and shook it until fell out. I then torched it again and with the extra four holes I was able to thoroughly burn out the gunk. I again used the cable to get any remaining packing and carbon. I repacked with small pieces of fiberglass using a chopstick to push it in. I made covers out of 3mm aluminum sheet metal, made gaskets out of silicone baking sheets, drilled holes and sealed with rivets and then painted black. I had to use JB Weld to level out the rear outside of the muffler that had the FM letters embossed. The whole process took a while but now I can completely repack the exhaust system making a big reduction of noise compared to repacking the silencer alone.