The FMF pipe fits OVER the FSW header whereas the header was designed to accept the pipe inserted into it.The FMF pipe is also stainless steel and does NOT come with a dixon clamp to secure it.....not sure why but maybe mine was left out.The FSW header comes with 2 slots cut in it to accomodate the clamping effect of having a pipe inserted into it....which is backwards from what I was doing.I basicall reversed the design.It was very simple to do as with a good wire speed and temp setup on the welder it will look like a TIG weld if it's spotted in....therefore you won't have to grind the inside of the pipe to smooth it out if done properly.I did however smotth the outside to eliminate the possibility of an exhaust leak.In the pics i had a set of 2 stainless hose clamps on for my test and tune before i added the permanent clamp.Even with the permanent clamp i took a 3ft piece of reynolds wrap aluminum foil and folded it until it was axactly 1" wide.....It takes up some space as Dixon does not make a clamp that will meet my exact needs.

[IMG]local://upfiles/4739/6F2F47875CD1488FB1BF0EAE50344233.jpg[/IMG]

 

maybe this will be better for pics if my upload works...
<img src=http://im1.shutterfly.com/procserv/47b7da34b3127cce8342b3214c8800000016108AZOXDhu2cta >

<img src=http://im1.shutterfly.com/procserv/47b7da34b3127cce8342b338cda100000016108AZOXDhu2cta >

 

nevermind it didn't work.... but either way the pic is of the FSW header and the FMF powercore 4 pipe.I got the FSW header with the provision for the OEM heat shield which will bolt right on it if you give it a good whack dead center with a soft face dead blow hammer.

 

Pipe looks good!

[IMG]local://upfiles/1878/3BF8F3B3681B4851B6820AEADC4D6DFA.jpg[/IMG]

 

Thank you.....I still don't think it meets my perfectionest needs.....But I will try.

 

So truckman besides the issue with the muffler having to go over the head pipe were there any other issues with this setup? Did everything else bolt up, no melting plastic. i would like to see some pice with the plastic on if you have any.

 

I used my trusty ballpeen hammer and clearanced a hair for the oil feed line and it has just a hair of clearance near the rear brakline master cylinder line so it's all good....no melting plastic and no contact at all.It sounds killer like a good healthy twin-cam 4 stroke should...a deep tone that's not obnoxious.I'll have to grab some pics with the plastic on later this week when the crummy weather clears out.besides my main issue of a factory deffect of kawi crossthreading the one exhaust stud...( extracted the stud and replced it) The install went without a hitch and i'd recommend it to anyone who is handy.I am running the 128DJ main with the needle on the 3rd clip position with a #40 pilot jet and no airbox lid for now and it really tears darn good.I also have a 47 and a 49 th rear sprocket and a new chain i can fit for some wheelie excitement....I can wheelie in first without an issue but that's with sliding my rear back on the seat....no different than my old kx125 so i don't think it's a big deal....overall I like it alot.