First things first: I had a call from my engineer that we had a little mixup with the numbers on the noise levels and as such my bike was too loud. So I sort of knew, that I had to do something about it. Luckily my muffler-insert-design already planned for such events, which meant the inserts are stackable and although the devil's in the details, i.e. how do you have this whole thing end up somewhat straight, it was a mere hour of fabricating to end up with a two-stage version. (The one originally in the TR1's exhaust ended up bent, when I took it out, so I couldn't simply cut that up as I had planned.)
Ground the old weld off and the tip can be driven out with (relative) ease. A quick measurement returned between 77 and 77.3 db of noise, which was way below the 81db mandated. And it sounded like a squirrel with diarrhea.
To please the eye of the official I quickly polished the mufflers and have to admit they came out rather decent.
One of the other challenges I had to face: As I didn't register the bike in my name BEFORE I started the conversion, I couldn't simply drive it to the department of motor vehicles, but had to borrow a trailer.
Already loaded up on the trailer, I realized that I had forgotten to install a reflector and this is exactly the kind of sh*te that might have gotten me into re-visiting them...
But I didn't and this is probably one of the most expensive eight page books I have ever bought.