I remember the build thread from the old site and you man, hope you remember how insane I am! That style of headrest is from a two seater Manco.
When making straight pipes we always did the old trick of painting, running where it popped and, then cutting the hoe when it stopped burning the paint as to get optimum length on the straight pipe. Was just curious, we've made straight pipes for dozens of bikes and always do it that way as well as making sure we clean up the exhaust in both the header itself and the block of the engine.