I want to cut off about 6 inches of my Jardine Highmounts and was wondering if anyone has done this and has any wisdom to impart. I'm thinking all I have to do is drill out the rivets and pull out the core, cut it to the desired length, cut down the core and put it all back together.

 

In a perfect world I think you've got it down. The problem is making it look finished and appealing rather than hacked. That's the trick part. Think about how you are going to cut the can - hacksaw? How are you going to keep its shape while you're sawing it? I agree that the Jardines are too long but shortening them properly is something I just don't think I have the metal working tools to do a good job. Just my .02

 

Which cans do you have? I've shortened some aluminum cans before with good results. Got a deal on a pair of D&D's and one was rashed so I cut about two inches off both so they'd match and they came out perfect. Louder too! For what my 2 cents is worth my process was to first disassemble the can. Drill out the rivets and use a rubber/plastic mallet. Be CAREFUL you can still dent the caps. If they're fairly new maybe they won't be so bad, otherwise a little penetrating oil will help out alot. I suppose you could also make things easier and cut right through the core too if it's frozen as you'll have to cut it anyway. Then I put a ring of painters tape around where I wanted to cut the bare can for a guide. I did use a hacksaw but just for a rough cut leaving a few mm's of material past the tape line. I even it off with a Makita grinder (a GV5000) and finally smooth the end out with a black and decker mouse and then wet sand and polish everything (for bare alum). You have to cut the core to the right length, tack it back together and reassemble. Then drill some new holes and rivet everything back together. Tape off around where you're riveting as the gun jumps and will scratch the can when the rivet breaks off. Also wrap the can or lay it on something soft to protect it when cutting it. I'm sure you can use a similar process regardless of the material, just work slowly. If you have the black cans be careful and you'll just have to touch up the very end of the can if at all. I guess same process for carbon minus the polishing. Has worked for me several times with good results. Good luck let us know how they turn out.

 

With CF you have to use high speed tools otherwise the stuff will fray, crack, and splinter.

 

Cool, thanks for the input guys, especially chaos. Hopefully I post some pics of my new bad *** shorty exhaust soon instead of a horror story.