Well, I finally finished the mod on my 1200 can. Basically, I took all the factory guts out and preserved the outside for a stock look. Is it any lighter? Well somewhat, maybe about 4 pounds. Did I gain any performance? I doubt it as I only have a butt dyno and it feels the same. It runs the same as before with no jetting changes. It seems to be as quiet as stock at idle and hiway cruse speed with just a slightly deeper tone. It is louder on heavy throttle usage though. I think overall the sound is much better than stock. It cost me about $5 for the parts and pieces I needed and could be less or depending on what “junk” you have laying around. The packing is courtesy of Johns Mansville (yup, the house insulation guy). Some of the tools needed will be some kind of grinder to grind the weld off the inlet end of the can, drill and tap for 3mm X .05 cap screws, the usual hand tools and a welder preferably tig or mig.
I didn’t do this before I took the can apart but I would at least drill all the holes for the cap screws before I grind the weld off the inlet end of the can. The weld I’m talking about holds the center of the can (the part that bolts to the mid pipe) to the outside of the can. The weld on mine was so good that I thought it was not a weld. You will have to drive the guts out of the can from the back to the front. In retrospect, I would get myself a piece of PVC pipe that would fit over the exhaust outlet. The weld pictured gave me fits as it protruded into the can enough that it didn’t want to let the end cap out. I ground it down before reassembly and everything went back together easily.