Just bought a carbon fibre starter kit and I'll be knocking up a mould to layup an end cone.
Had an hour in the garage while the kids were making fairy cakes and the baby was asleep.
Link pipe now cut to the correct length and welded to the main system.
The whole lot will come off now, get welded up, then cleaned with scotchbrite and polished up.
The rough cut steel bracket for the can hanger will get used as a template to fabricate an ally one.
Got the link pipe welded to the headers last weekend and gave it a tidy up with the grinder. I managed another couple of hours this morning and made some proper progress. The headers got attacked with a flap disc and wire brush on the angle grinder, a dremel, scotchbrite pads and some stainless cleaning solution. They've come up better than I could have expected for the minimal effort, but I can't be bothered to put in too much work this is as good as it gets. I fitted them and clamped the end can on, checked clearances and it's all good. O2 sensor refitted and I started it up to burn off all the crap and residue from inside and outside. Last thing to do is cut out a piece of ally plate on the bandsaw, pop a couple of holes in with the drill press and then bend it into shape with the help of mr.blowtorch.
It's loud, but not ear crippling. However I think I'll replace the cheap dB killer with a decent one all the same.
Stock vs Badger Build
A mate had a Leo Vince can on a 650gs single, it came with two baffles. The usual dB killers type and a strainer type for before the can. Might be worthwhile looking into if the noise is too much for you as it made a real difference on his bike. Either way you will have the usual problem that it's a small can with little packing volume.
Looks clean, but maybe a bit too old school for the bike's lines?