Hello,
I installed mine with no problems at all. Yes it is a tight fit but all worked with out a hitch.
Desert, why did you use a dremal? All you needed to do is put a film of anti-seizing greese on the header part and all slides on perfect!
Yes the joining part of the header pipe and the baffle are a very close fit by the frame. There is about 1/16 of an inch space or if that between the frame and the pipe joining connections.
Other than what was mentioned I have had not problems with it at all.
If you need more assitance on installing it you can pm me..it only should take 15-30 to install with out breaking a sweat.
Regards, Fly