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I watched Andy, designer of the A&A mod, while he did the work on my 2001 C5. He very carefully placed the bypass pipes into position and then outlined for the holes. To finish the holes he used a grinder to better shape the holes to the bypass pipes.
From what I understand the final sounds are dependent on these holes not only being placed in exactly the right spots but also that the holes are the right size and shape. Andy made many many trial bypass pipes until he finally arrived at the sound that he and others found most pleasant.
I'd say the holes are 1-1/4 in by 1-5/8 inch. I traced around the A&A tube witha black magic marker then had the holes cut slightley smaller, then used a Dremel tool to smooth up the edges before the welding.
HEB
2000,triple-black-vert. :chevy