Thanks guys. Cam chain tensioner is going back in this weekend with all new parts, hopefully no more clatter.
Scored a no-longer-available Yoshimura 2 into 1 pipe off of the other 250 forums last night, it's supposed to be in the mail today or monday. Also scored a gauge cluster, I'll be swapping out the speedo/odometer into the new one since mine has broken mounting pegs.
Pics:
I'm going to sandblast & paint / possibly powdercoat the pipes.
Mitch