ok - well i spent 6 hours on it last night - taking my time and making sure i did everythign right. (Just in case - I stopped at Walmart on the way home last night and bought some undercoating..
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I stripped the rear fender back down - smoothed it up and let the filler sit overnight to dry in the shop. I prepped, primed, and painted the side covers, air cleaner cover, and gauge housing gloss black without a single issue, run, crack, or spec of overspray. I let them sit to dry. I started removing the gas tank, but I dont have the tool to remove the fuel line so I gotta find that today. Probably cost $40 or something
I started the pipe-chop. I removed the pipes from the bike, removed the mufflers from the pipes, and then chopped the connector pipe off the rear cylinder exhaust pipe and welded up the hole. I thne took the 4" mini baffles from J&P cycles (1 1/2"x 4") and added a rear half-cap to the baffle. I then welded the baffle to the end tip of the stock headers and will now line up my chrome drag pipes to get the length and tone I want and then weld the outer chrome pipe in place liek a long tailpipe for a car. The stock heat shields will be used and will make the pipes look like they were almost factory!
pics will come this weekedn as I start finishing things up...