Please forgive the crudity of the explanation, but I get so many compliments on the sound of my "Custom" muffler job, but I think its a tad louder than I would have preferred, but if you have a Dremel and patience its easy to do. Its even easier if you have access to a blow torch, which I didn't. The operation is basically removing about two inches from the end of the smaller nipple, or outlet pipe, or spark arrest, that comes out of the back of the pipe. Basically, you want to remove, what is essentially, the spark arrestor.
This method should work on most pipes that allow enough space in between the two outlet pipes. Usually, their is a very large one and a very small one. Also, this would not work with a pipe that uses packing to achieve the baffling. It will only work on a pipe that is "Chambered."
To remove the allen bolts on the TLS and other Suzuki pipes; use the flat Dremel grinding disk to weaken the bead just enough to allow them to break free with a ratchet or wrench. be very careful not to touch the end cap for cosmetic reasons. I replaced the bolts with new stainless steel ones, again for cosmetic reasons. With the VTR this step is not needed as their is no endcap.
Drill as many holes as possible, as close to the diameter of the larger pipe as possible - This is where a blow torch would have been nice. Then use a dremel side awl, mounted in a drill, to cut in between the holes that were just drilled. A side awl is a drill bit that cuts on the side instead of on the point. The heaviest side awl that dremel makes is designed for aluminum siding. So, in order to make the side awl work on stainless steel use a lot amounts of WD-40 or similar lubricant, and go slow. Let the bit do the work, avoid the temptation to press hard.
After that, and this is the hard part. Using the Dremel cutting wheels, insert the Dremel into the outlet pipe, far enough to go behind the outer wall and start cutting from the inside of the pipe, all the way around. This requires a great deal of patience and a steady hand. Tilting or shifting the Dremel causes the blade to shatter. (wear eye protection)
Once this step is complete, replace the end-caps or grind away the jagged edges. Make sure to use loctite on the three bolts that hold the end cap on. Again, on the VTR, I used a grinding wheel to clean up the outside edge since their is no endcap.
Voila! You have aftermarket sound with stock appearance. This has worked in my favor because many police officers will think you have stock exhaust.
