Swapmeet, I'm in the same situation with you on reinforcement and defoam/refoam. For reinforcement, I'm probably going to do 3 layers of 7781 and 1 layer of Kevlar. Maybe just 2 layers of 7781 and 1 layer of Kevlar. Should be strong enough for my riding style. For refoam/defoam, I have not...
Just the front of the tray as in the front wall? It's possible to do all of that with one sheet but you can get two just in case. You can never go wrong with an extra sheet for later.
Ummm.... Are running a stock exhaust? Your post said so but the picture says otherwise. It's not necessary to run a dual cooling on a stock sxr motor and exhaust. I have a wetpipe on my sxr and running single cooling. It stays cool enough, never overheated.
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