Don't count out local muffler shops for something like this. Here in Indiana I have a favorite muffler shop that created me a full brand new 2.5" custom bent dual system, with a crossover and two 50 series Flowmasters. $304.35 parts, labor, and tax, fully welded, excellent quality...and I never had to even get my hands dirty...

This was not a fluke...I've used them many times over the years for other projects and always am greeted with the exact same high quality/low price. And originally I was referred there by other equally satisfied gearheads.

I know this is too far for you, but for anyone in Indiana, this little shop is called Mufflers & More, in Westfield, Indiana. Don't expect chit-chat and friendliness. All business.

Like you, I was shopping high and low for a system to install myself, having completed all my own frame rail/floor replacements. Then I called this shop for a verbal quote, 68 Fbird convertible, 2.5", duals with crossover, pair of DynoMax mufflers to fit. The dude just gruffly told me "we're a Flowmaster dealer". Then silence.

OK...I'm not brand loyal...I then ask "so how about same system with a pair of Flowmaster 50's." They told me "about $275."

long pause. that can't be right.

I said...INSTALLED?!"

"Yeah."

Heck, I'm thinkin'...I can't even BUY a system for that price, much less go thru the headache of installing...so what have I got to lose?! So I made an appointment, trailered my open-manifold machine over there, and dropped it. Later that day I picked it up. When they apologized that the bill came in $30 over quoted budget due to difficulty working around my custom subframe connectors and drop crossmember...I didn't blink an eye and I let them know I was still VERY very satisifed!!

Of course this doesn't get your header problem solved, but after you find some headers and get them bolted on, make some phone calls and see what some local shops will bend up for ya...you might be pleasantly surprised.