When I installed mine it did the same thing, I figured I was screwed but when I cooled down and so did the pipes, I started over and loosened all of the fasteners and started from the rear of the bike tightened the bracket then tapped the head pipe into the muffler a bit further and then went through the rest and tightened each part up and kept checking for clearances. As long as everything was about even front to rear I moved on to the next fastener until all were tight and then after a couple hundred miles went back and made sure they were all tight. No more hitting. Real small moves make a big difference on these bikes.
I wish it was just the heat shield. There is a cut out near the cam cover so it's the actual pipe touching.
Did you tighten up the exhaust hardware starting at the aft end and then continue working forward?
It might seem more natural to start at the exhaust ports at the forward end and work aft, but D&D stresses that you need to start tightening at the rear.
Tom
How did you guys with fatcats mount the passenger peg? Was the supplied bolt to short?
I'm interested to know as well. I ended up leaving my passenger pegs off as I couldn't get them to fit. I thought D&D offered a bracket for them, but I've never done a lot of homework as I ride solo 99.9% of the time anyway.