brancher, there are many posts here in the cruiser forum devoted to this exact topic. Just do a search on yoru deisred keywords and I guarantee you'll get all kinds of information.
I myself started such a thread about a month ago when I was researching aftermarket pipes for my Vulcan. Most of the folks in here are partial to Hard Krome and Vance & Hines. But you'll find some Cobra and Jardine fans too. It all depends on what your goals are, how much noise you want, what your budget is, and what is available.
I recently installed the Cobra Slash Cuts on Sept 23rd on my
04 Nomad FI. See Posting "Cobra Pipes-04 Nomad FI".
ISpeed77 was right about the loosening heat shields to start. About the rust I don't know yet. Time will tell. I had to make 2 adjustments so far. One to the Front & Rear Heat Shields. This was done on Sept 25th, two days after the install. This may have been due to being too careful on the tightening up of the clamps on the heat shields. The clamps from Cobra are much cheaper than the factory clamps. I've done around 100 miles so far and everything is still tight. Again time will tell.
With the installation of new pipes the engine will definately run lean. You'll need to install some brand of Digital Fuel Processor to solve this. I'm waiting on a PCIII/USB scheduled to arrive via UPS on 10/05. It is also recommended that a High Flow Airfilter be installed to get the most out of your upgrade.
Check out this web article from RideGear: http://street-bikes1.ridegear.com/store/section/Street_Exhaust_FAQ.html
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