Right, full system installed on bike, on bench, on carpet in front room (got slapped for that one!). The problem with the welding jig is the angle of the slash cut. As soon as you rotate the pipe to allow the connection to cross over and bolts for the hanger - which did align correctly the slash cut twists in a clockwise direction. If you read back through the previous posts, Paul Bryant explained it a lot better I have. I spent numerous hours in the garage trying to fathom out why it was not aligning correctly. It was only when the photo of the pipe in the jig that it was sooooo obvious - nothing to do with my limited mechanical knowledge but the construction of the pipe was wrong!!! I was told the bracket was wrong, attached to bracket upside down, back to front, bracket caused twist etc...really frustrating. Oh, and the special paint peels off too!
See photos: