Baja Exhaust system 1600 vs. 40 horse

[questrov]

Needed to replace the old exhaust on our new (to us) 67 Baja Bug. It had the EMPI quit muffler https://www.jbugs.com/product/3369.html and heater boxes.

Local shop sold us same but said they don’t make them for 40 horse anymore but the 1600 version will work, just bend the tubes in a bit.

Seems “a bit’ is more like an inch! Easy to bend the tubes but can’t get the flanges flat enough to seal. Afraid to do any more bending will likely wind up with a shiny new broken exhaust.

Not sure what to do now, thinking about cut and weld but not sure my skills are up for that and there is really no straight part to cut an inch out where one could weld all the way around.

Any suggestions or thoughts? Surely somebody has already been down this path...

[oprn]

It has been about 40 years since I played with a 1200 so I have no idea what is available now. Try posting in the vintage speed section and see what they are doing.
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