XR 250/400 sparky question

[cowboyona426]

Guys, this blue rider has a a few quick question for you. I'm helping my dad fix up his 85 Suzuki DR 250, and it needs a new sparky. I doubt I could easily find an aftermarket or OEM replacement, so I borrowed a stocker off an 01 (I believe) XR 400 from my uncle to see if it will fit.
Question 1- is the 250 pipe a smaller diameter than the 400 pipe? The 400 pipe will fit, but it won't quite clamp down to the DR's header tight enough. The solutions I've come up with are (1) find a different gasket that is thicker OD, or use some aluminum tape on the DR gasket OD to thicken it up and (2) cut the end off the 400 sparky and the DR sparky and weld the DR end onto the XR pipe to make it fit properly or (3) try a 250 sparky.
Question 2- to clear the frame on the DR, the lower mount that bolts to the subframe will need to be cut off. Would this need to be relocated, or would it be okay to run without that lower mount?
I was actually surprised at how close in shape/length the 2 pipes are- the 400 pipe will fit with very minimal modifications! We'll need to fab an upper mounting bracket (or weld a new one onto the DR frame) but that's no biggie. The only thing that scares me is how dang heavy that pipe is : but this is a budget-based project so an aftermarket pipe is out of the question. Besides, the old man doesn't really need earth-shaking performance anyways The 400 sparky is a little shorter than the original one, but that thing was a bazooka! The shorter length shouldn't be a big issue. I'm starting to think that a re-jet will be necessary though.
So... that is where I currently stand on this project... any comments or other suggestions are more than welcome.

[unfrench]

Wish I could help. My theory is that by the time I was done fixing my old bikes (Time & Money) I could've bought a 3 yr old+ modern bike -easier on my old skeleton.

[Honda_Rider_XR]

USE TIN FOIL!!

that stuff is soo great at making the connection, you have no idea!