I went out fiddling with it tonight. Went through this procedure and it fixed the fitment to only require a very minor amount of upward pressure on the end of the muffler to line up flawlessly.
1: Loosened the muffler mount.
2: Loosened the Clamp.
3: Loosened the Headers.
4: Wiggled the muffler around a touch and heard a faint click, the sound of metal shifting from the front end. Clearly the headers moved the smallest imperceptible amount.
5: Used
slight upward pressure on the end of the muffler and the footrest slid right in, so perfectly aligned.
6: Tightened in this order: Front bolt on muffler hangar, installed footrest and panel and tightened, tightened band clamp, tightened header.
7: No exhaust leak at the head, the tiniest little flutter at the band clamp (Could tighten more and it should go away, was trying to not crush the pipes), and a smoother sounding idle
Next step in the process, load my CES tune instead of my Hybrid Tune I had been running but.....
Ok so... my OBD2 FTDI cable is broken :/ New one is on order, so tuning will have to wait until it arrives.
Re installed all my data-logging stuff tonight for OBD2+Wideband capture. Understanding that these headers will accomplish both improving the scavenging effect and the ultimate flow capacity I have come across a somewhat surprising effect.
Not wanting to take the bike out tonight, I started it up and let it idle to see how much the CES effected my idle AFR. To my surprise it is actually a little bit richer at idle than it was before, but more than 1 full point leaner just off idle, when cracking the throttle the smallest amount possible, at about 1100 RPM. Looks like just adding a set % of fuel when installing headers is very much not the right answer.