I debaffled my stock Nomad 1600 mufflers this weekend. Just used a 2" hole saw (1 3/4" or 1 7/8" probably would have worked great, 2" may be a little big), and it was extremely simple. One cut, the baffles slid right out using some needle-nose pliers to pull them out. It took a little bit of time to cut through the welds, but with some patience, it wasn't all that hard to do. This was my first major mod to the bike and I didn't think it was all that hard to perform.
I love the way it sounds!! I don't think I'll do anything else to the exhaust after this. Maybe some intake and computer mods, but as for the sound, I love it. No backfiring or "popping" after this either, but it's only been about 15 miles since I did it.
Matt "MO" Moore
'05 Blue/Silver Nomad 1600 - Darkside
Vulcan Baggers Association (VBA) member # 1250
"There is no normal life... there's just life. So get on with it!" - Doc Holliday