Thanks for the tips.
Actually, popping on de-cell is definitley the result of a lean condition.
A long time friend owns Factory Pro, they know a bit about tuning and have
help me out on several singles I've owned.... Since my XL600R back in 1987.
Actually, they kind of "invented" jet kits and dyno tuning...or re-invented it?
Check it out.
http://www.factorypro.com/
BTW, swapping out to a larger pilot eliminated the popping of decell completely. Sorted. The bike runs perfect, much better than stock.
I'm hoping the fuel economy will still be over 50 mpg.
You are correct about mixing of disimiliar metals. As a former A&P mechanic
(aircraft) I am well versed in electrolosis and the results of same. A good heads up nonetheless.

I think there are a couple nonstressed points on the DR where fasteners are overbuilt. Its these I will focus on.
I'll be riding in mixed conditions but lots of rough pavement, dirt roads, pot
holes and such. No motocrossing or desert racing mind you. I have a race
bike for that.
I'm working on Stand offs to protect soft luggage from the hot pipe.
I have a proto type, will post pics at some point.
Cheers,
Patrick