Update. After several different attempts to get the pipe on, I still kept telling myself I wasn't going to cut it.
And in the end, I didn't have to.
I came up with an idea that was silly to begin with but crap...it worked.
The Trapp has expanding joints already cut in the pipe. The header is simply to thick to do much with (minus cutting it) so I decided to run it down the road a mile just enough to get that baby nice and warm.....but not too hot of course.
I figured since the muffler already had joints cut, it would expand much easier and faster than the header.
So I loosened the bolts and clamp I put on as a temp and gave it a few good wacks with a rubber mallet.
It still didn't get all the way to the flange of the header pipe but it moved just enough to fit real snug and not have any leaks. So I tightened everything up and wa-la.
Note I did settle for only 1 screw, but I am hopeful that it will keep it on tight enough.
I'll still have to monitor it of course but I think its a fix.
Now on to the carb, but its too rainy outside to take it for a stroll. Forecast rain for the next two days......but just the initial start up was well worth the headache.
It went from a Stinger Sewing Machine to an actual bike. The sound quality alone has me excited.
I have the stuff for a rejet already here but I want to wait till I can see the difference with just 6 disks and stock jets.
A friend has an 96 savage with a sportster installed and he was blown away with the sound. I think its going to be fun when I take it for its first test run.