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For this exhaust sytem, we are using 2.5" steel pipe and Ron Covell's donuts.  The donuts allow for really tight bends without any kinks.  Every joint is carefully fitted, TIG welded, and sanded smooth.  When completed, everything is Jet Hot coated.

Here's a shot of the pipe coming off of the left header.  You can see the nice radiuses the donuts provide.
The pipes wrap around the rear and drop down below the gas tank (not in picture).  The ends have a slight flare added to them.

Here's how the exhaust passes through the frame.  For a clean look, nothing is below the frame rails.

Here's a shot of the finished, coated system.  With minor care, it will look like this for many years (and many miles!).