Nice looking solution NEHI. That does look like the ultimate plug off set up!
Does seem like a lot of work though. I really like the idea of using a pipe plug especially on the bottom port but unless I had the exhaust off for another reason that aint gonna happen!

9/16 cup plugs bought at NAPA have been working just fine on the top for over 30,000 miles now on my '97. I cut the bottom pipe off about 1/2" from the foot, folded it over & welded it shut then reinstalled. Only had to pull the engine guard to gain access.
Nice work. I have seen 1/8 pipe plugs in the allen wrench style in aluminum, brass & steel. You have to hunt for them but they do exist.

