Wanted to get just a bit more exhaust tone out of my '01 Trophy 900, wanting the exhaust to overcome the cacophony of clatter from the Hinkley engine, but not wanting to be as loud as the D&D aftermarket cans, and being a frugal Yankee at heart, I opted to drill out the stock cans. I used a 7/8" hole saw to cut a couple of holes in the internal baffle plate. I figure it would reduce the exhaust restriction just a bit too, which would be a good thing for power.
You can pickup the hole saw and extension (shown below) at any Home Depot in the USA. They are fairly expensive, costing around $20 altogether (you buy the extension, drill/arbor and saw separately), but I already owned everything below from a prior job.
You can see the two "slugs" that were removed from the internal baffle in that picture too. The result was almost no noticeable increase in sound.
On to stage 2...
Next I marked the end of the exhaust can around the crease in the metal with 6 equally spaced holes using a Sharpie permanent marker. I first drilled out three oif the holes in each can, and then decided to go all the way and drill them all out. This raised the exhaust note to just a nice mellow rumble.
I still need to de-burr the new holes, as can be seen in that second picture. I'm very pleased with the results and especially so at the cost of the modification ($0.00).
That is all...
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