We started the last session by finishing off the suggested jetting changes.  The last piece of the puzzle was to switch to a size #25 pilot jet.  Once again the float bowl was removed and the correct jet installed.  So with a new needle, main, and pilot jet, as well as a new needle seat, we should have a good spot for a baseline to do fine tuning... when the bike gets running!

We have also come to realize that the side numberplates of the Manx seat won't work with our choice of intake manifold... and for a few other reasons, we also decided to eliminate the side plates from our seat. These have to be removed slowly and carefully, so the Dremel tool was fired up once again. 

Steady as she goes... note the mask and eye protection!

While the seat was getting trimmed, Mr. S finished welding the new seat mount to the frame, after being tack-welded in place previously.  Once alignment was checked and re-checked, we went ahead with the permanent solution.  Next, the remaining mounting holes were drilled once marks were made.

Over the weekend, Mr. S bought some slip-fit exhaust pieces from Canadian Tire as a trial fit for the exhaust.  This solution appears to be workable, so the plan is to weld extensions on to the current pipes, so that the megaphone exhaust will clear the rearsets, as well as the rear axle.  The end result won't look pretty, so the headers will have to be stripped and refinished somehow.

Over the next while it is finally time to tackle the wiring.  Not sure how things will go... we've got the original wiring diagram to go by, as well as several examples of solutions others have found incorporating the more modern components like our Pamco kit and PMA alternator.  That, combined with the use of the stock handlebar switchgear, as well as safety requirements, will be a test.  Might as well dive right in!