I did it – thanks to John and Ken for daring to trash their Jetboils first!
The cut down with a hack saw was very easy and quick – I cut it just above 2 cups capacity – a hair over the 500 ml mark on the pot. Sanding was also very easy and quick. The the cut down Ti pot is very sturdy. The loss of the rolled edge had virtually no appreciable effect. In this particular case the worries about this were TOTALLY unfounded. I guess the Ti is already very rigid, and the Jetboil pot is reasonably beefy to start with. The resulting edge (after sanding) on the pot is smooth and isn't going to damage anything.
I got a little finicky with the cosy, which was the main time drain here. I modded the cosy that comes with the pot – cut of the velcro strapy things and the handle. Turned it inside out to get rid of the logos, "hemmed" the edges cut off the excess material, and sewed the handle material back on in the new config. My wimpy sewing machine had a bit of a hard time. I'm sure some of you could have done a much neater job. I definitely needed to use a sewing awl on the reinforced thick part where the cosy was originally joined and the the handle got re-sewed on after.
Here is a picture complete with Ziplock replacement top and hotlips.
Weight here includes burner inside.
This is really now about the weight of my sidewinder alcohol stove setup, but with the fuel efficiency and convenience of a Jetboil. It is now small enough to be a really comfortable coffee cup and as john demoed before a small bowl, and has the capacity to rehydrate anything I ever would use in a single boil. In the very rare case where I need more that 2 cups boiled (personally never happened for me) the Jetboil is so fast you could do an extra boil in a minute or so.
Personally I feel like it is a big win for simplicity as well with basically only three parts, pot, top and burner. More or less built-in windscreen and primary lighter. There isn't really room for a spoon inside, but there is a lot of extra space both in the pot above the burner and in the space under the heat exchanger for extra matches, cleaning cloth, etc.
Every once in a while I feel like I approach personal nirvana with an item of gear and I think I am now there with this as a solo stove.
Interestingly enough the addition of the hot lips, which btw tucks nicely into the cosy now, has the originally-unintended effect of allowing the ziplock top to lightly snap on. Don't get me wrong it is going to fall of if you turn it upside down with water in the pot, but it should less likely to blow away in the wind before you find a rock.
