I don't mean to shoot down your plan but there's a ton of other "tried and true" options out there. There's a wealth of info on swapping over to SBK forks as that one's been done 1,000 times. You could also pick up a good set of late model SS Showa forks (which already fit) and spend all this time, money, and effort on getting those suckers worked over into a simply awesome set of forks. Just some ideas... 
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'04 800SS...Strati pipes, K&N air filter/air box, Afam 42t sproket, DID chain, Evoluzione fender eliminator, Bridgestone BT-014's
'05 749s...Evoluzione fender eliminator, Termi 54mm full-system, PCIII/Custon Map, 41t sproket, DiD chain, CF Hugger
My Garage
"Freedom, for those who fought for it, has a flavor the protected will never know"
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