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Discussion Starter #1
Decided to do the muffler chop, rather than spend money on an aftermarket can. My goal was to shorten the stock can by several inches to enhance the look, and to also get better sound. Originally I wanted the can to be about 15.5 inches long, but after reviewing the internal baffle design and determining what I wanted to change, I needed to keep the can no shorter than the 17 inches shown here. I did not want to produce a “loud” bike; only to get a deeper tone and maintain the stock back pressure.

I know that this is probably the “less radical” muffler chop, and yes I wanted the can to be slightly shorter, but I’m very pleased with the results. I kept the honeycomb catalytic converter (it creates most of the back pressure) and I also kept the internal baffle walls, but created a more direct exhaust route. The sound is excellent, with a nice deep tone, especially at idle. Prior to installing the rivets (used 1/8 inch stainless steel “short”) I went for a short test ride, hoping that the snapped off drill bit in the bottom hole would hold things together during the ride. It did not, and the resulting loss of internals immediately rendered poor performance. After picking up the pieces, and I was lucky that the exhaust tip was not damaged, I got everything put back together and installed the rivets. I keep the internal fiberglass wrapping (it keeps the outer can from turning yellow), and had to use a new top quality drill bit to cut the rivet holes. Also, a good flat file is the best way to produce a final edge on the can. Thanks to all of the previous folks that posted chops; all that information was helpful.

http://i637.photobucket.com/albums/uu97/zuberjohn/010.jpg
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Discussion Starter #9
how does it sound?
The sound change is excellent. A much deeper tone, expecially at idle and at normal riding RPM (3500--5000). Power is the same...no change. Overall sound level, not too much higher, but some. My goal was to achieve a better sound, not to make a louder bike. I essentially removed the middle section of the baffle, but still retained the internal walls. The exhaust routing is now more direct, by cutting the pipes in the middle section.
 
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