I just did this job, here is what I used:
- cobra 1.75 t-clamp
- cobra 1.75 heat shield.
- 5/16 grade 8 bolt for the rear hanger - I'm using only one bolt.
I couldn't get the tin can to wrap around the header pipe, so I used about 4 layers of aluminum foil. So far, no leaks. Cutting a tin can is a skill that I haven't developed yet
Yeah, you have to remove the whole exhaust. When you install, you'll loosely clamp the muffler to the pipe (with gasket), then tighten the header, then the hanger, then the t-clamp.
Once clamped down good, test for leaks around the joint and at the header - I had a leak around the t-clamp that was obvious - I could feel it put-put with my hand.
The muffler install in the tech section was a good help. Read that a few times while you're waiting for delivery.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1298689417