Andy, thank you for taking the time to answer my remedial questions! From what I've read on the technical stuff on the forum the HRC card has its limitations for a road bike. As I understand it, the HRC card means that you lose 85% of the electrics? Getting mine re- programmed will have the same effect right?
Binning the air box is easy enough, I'm sure I can find some compatible air filters unless you have something you recomend or I can buy on the site? Expansion chambers, pretty straightforward. The key? Offset key haven't seen anything about that?
I'm not looking for a bike that's going to win the next 250 Pub GP,  I'm looking for something to have some fun on at the weekends. It also doesn't have to be the fastest MC 28 out there. Reasonably  reliable, not too much stress on the engine and 10 to15 hp on stock and I'll be happy! 
Sounds like any expansion chambers will do + air box work and the HRC O30 card plus splice should pretty much set me up? Is it worth reprogramming the 010 and 020 cards which came with a bike to 030? Do you have a preference for which expansion chambers?

J