Thanks for the great idea! After reading the entire post, I started digging through my tool chest and realized that I had everything I needed to do the job. The first pipe was a learning experience....took 3 reinforced cutting wheels, a wooden dowel, hammer, and lot's of swearing and sweating before it finally came out. Once it was out, I was able to see the error of my ways. Second pipe took less than 2 minutes and about 1/4 of a cutting wheel, with no sweat, no swearing and no need to use the heavy artillery.
The difference between the two? Simply how far into the tube you choose to make your cut. If you look closely, you can see a slight ridge around the inside of the tube. This is the weld bead from the assembly. The trick is to make your cut 1/4" beyond that weld. Set the mandrel of the cutting wheel, and then make a quick test "scratch" inside the tube to see where you are at for depth, then adjust the mandrel in the chuck of the Dremel tool until your cut will taking place 1/4" or or so past the weld marks.
Sound is really good after the mod. Throaty growl at idle with a lot of bark when you ask for it. But at cruising speeds, only a barely noticeable difference in sound, which passed the wife test with flying colors. I only have 45 miles on it since I just did it last night, but we are doing a couple of long rides with my fellow Red Knights this weekend and I will see how it does with a tank or two of fuel to check the mileage (consistant 42 mpg running 93 octane with 10% ethanol).