I converted the cans on my '01 'busa to straight race cans like an aftermarket race slip-on.
It was a lot of work but I'll tell you all how I did it.
First, I ground the bolts on the back and took off the crome tail pipe. Next, I used a dremel with a cut off wheel to trim the rolled edge of the outer can off. When that was done, I slid the insides out...I had to be pretty aggressive to get it out.
When it was out, I cut the packing off of the outside and decided that there was a whole lot too much metal there. The inside of the can has 3 small pipes intersecting 3 larger chambers. The exhaust has to double back going from tiny pipe to large chamber like 3 times.
I decided to keep things simple and torched off the front and rear of the inside part. I then went to my local metal supplier and bought some perforated steel. I was able to get a piece of 2.5" muffler pipe as scrap from a muffler shop and went to work making the sheet of perforated steel round. Once it was more or less cylindrical, I trimmed the excess and clamped it tight. About 100 spot welds with the MIG later and I had a solid tube of perforated steel.
The tricky part was welding the tube to the old parts of the muffler and keeping them straight and lined up so the tail pipe would go on the right way when I was done. I had to cut holes in these pieces to accomodate the 2.5" diameter as well. I put the pieces into the muffler with the tube sandwiched in between. When I was convinced I had it centered (or at least close enough), I tacked them together. I pulled it all out and welded it solid.
After that it was just a matter of wrapping some packing around the tube, and slipping it into the can.
I drilled 3 holes in the rear of each can and put aluminum rivets in to help hold things together. I then put the chrome tail pipe back on and was done.
I'll post some pictures today of the finished product. There's only a few little things that give away the secret.
They sound great. The most rumble at idle I've ever heard out of a Hayabusa.
<!--EDIT|DTechnologies
Reason for Edit: None given...|1082467454 -->