Here is a video of the rattle:
The issue: Look at the following image: There is a gap that gives lateral movement, which is causing this annoying rattle anytime the value opens (which is at 2000rpm, or when you manually open/close the valve).
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Previously solutions from researching the forums
1) Have the exhaust replaced under warranty. Yes, but it's a design issue, so chances are it will come back, which it has done with a few people who have had their exhaust replaced.
2) Grease it up... Nope, it will still rattle.
3) Copper wire wrapped around so that gap (in the picture) does not move....
Today I found a solution that has worked so far! And it cost less than $5.00
The idea is to close that gap so it can still freely move, but is tight enough so there is no longer any lateral movement.
I bought 2 clips from Lowe's (99 cents each), and some anti-seize metal grease).
Slid them on, greased em' up just to make sure they move freely, and BAM! No more rattle! Quiet as a mouse!
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Day 2... Still no Rattle!
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The valve opens when the connector gets 12v on its control pin, so if you intercept the control signal from the ECU and just replace it with a constant 12 volts, the valve will stay open all the time. I've also made a few 'always open' switches for people who didn't want/need all the GPS stuff in the Track Nanny.