Hello.
I work very long hours away from any PC terminals have not had a chance to read the posts,that is why I have not replied sooner.
If you make the reducers about 3 inches long,slide them into the header pipe end at the junction where the muffler clamps on with the small taper facing towards the rear,at the muffler shop they will expand the pipe so that it will slide in very snug,the rear end taper can be any size you want ,I have tried 35mm.30mm and 25mm all depends on how much noise you want to get through.
I just had the muffler men make up the three different sizes,it takes no time at all with the gear they have at hand.
I have even experimented with some stainless mesh tack welded over the smaller end to difuse the gas flow.
So all you do is keep experimenting till you get the sound you want.
Cheers.
Stevew