I would like to thank @npc, @Gutta Perka, @Fenwoodian and the others in this thread that figured out this mod and how to do it. I am just going to lay out in detail the instructions with pictures for what they figured out.
NOTE: Do this at your own risk. You are working on a 'DA*' lens worth maybe $1,000. Think carefully if you want to take the chance of ruining your lens!!!!!!!!!
Here are some detailed instructions:
- First, there is no need to remove the bayonet. Just the smaller plastic ring that holds the SDM contacts.
- Locate the SDM contacts and remove the two small black screws there.
- Gently pry out the black plastic SDM mount with the two gold contacts. These are slip fit connectors, like electrical connectors, so just gently pry on each side back and forth until it lifts out.
- Locate the three silver screws holding the black ring in place. There are four screws in the ring. Three located at 120 degrees from each other and a fourth just to the right of one of the others. Of the pair you want the left one. Remove these three screws. I used a rear lens cap to put the pieces in to keep them safe. These are very small screws. They are also JIS so make sure you do not strip them.
- Now with the screws out the black SDM ring and the baffle will just pull out in one piece.
- The baffle is glued with something like rubber cement to the SDM ring. I used an Exacto razor knife to cut the glue away, but it was soft enough I think you could just break it. Note the scratches on the black baffle, these were present on the baffle when I removed it and were not caused by anything I did. Not sure if they are from manufacturing or if something was rubbing on it inside.
- Now the baffle and the SDM ring are seperated, clean up any glue residue on the ring. I just used the razor knife.
- Now we need to remount the SDM ring. Place the ring back in position, aligning the two rectangular holes with the two gold female SDM contacts. Replace the three silver screws.
- Now gently replace the SDM contacts by pressing them slowly back into the female connectors. Replace the two black screws that hold the SDM contact plate in place.
- Now insert the cardboard replacement baffle. Dimensions of the original are roughly 30mm wide so you need a cardboard strip a bit smaller than that and long enough to wrap around itself. I just rolled it up slightly tighter than needed, inserted it and let it unroll in place.
- The project is done, put the lens on the camera and test. I gave myself nearly a heart attack as mine would no longer auto-focus. I forgot I had the camera in manual focus.
After brief testing I can say that most, but not all of the, vignette has been removed. Unfortunately it is dark and overcast today so difficult to do good testing. From what I see there is no vignette below 85mm and only a slight darkening in the corners above that. This is at f/4. The sharp circular vignette is completely gone and I do not think the lens is much worse in the corners now on FF than it was on APS-C.