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on mine john left the stock tubing off the manifold. right after the bend is where the new pipe went. with a a very smooth merge where they come together

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What gauge/wallthickness is your tubing? If it thinner then 14 gauge (.075 wall) it maybe difficult to weld to the fanges.

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The size pipe really depends on how you want your power curve to be... mine is pretty high up there compared to stock (but thats where I keep the engine so it works for me)

 

I run 2.0 from the heads to the cat, 2.25 to the muffler (midpipe) and 2.5 out from the muffler. (all measurements in inner diameter)

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I'm strongly considering one of these http://www.discountconverter.com/converters/images/8015.gif for on the ER-27 exhaust when I get to that point, also comes in a 2-1/2" size. Equal length lead pipes, with a cross-connection is the best route for power gains. Any bends in the system, should be as smooth as possible, too.

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