Ofcourse my new CMIs Unitops will not fit. The outside pipes do not line up with the holes by about 2". 1990 Sonic 31 SS' transom is not wide enough to drill new holes.

Can a plate be made to go in between the head and header to curl the pipes in to line up with hole?

Or

Can a 4" section of the pipe be cut out and the flange be welded back on? Would that cause reversion?

Figures my mechanic has had the boat for 3 weeks and calls this morning to tell me. Now it looks like no boat for my extended holiday weekend Here we go again!!

Being off 2" your only real option will be to get new tailpipes from CMI.

This sounds frustratingly de ja vue ish,, I machined some angled aluminum plates for Paul's Scarab headers, that went between the exhaust and headers to make the pipes the correct angle with the transom, with a gasket on each side,, needless to say it was a lot of machining and it didn't work out too well,, they lined up perfectly,, but they leaked... I made the holes in the plate the same size as the gasket holes which I thought were the same size as the header holes, turned out they were not,, I think with some fine tuning they would have worked,, but how reliable they would have been is another question,,, wasn't worth the risk of reversion or some expensive engine damage to save a few bucks on the wrong headers..

Why Don't You Get New Tips Made With The Angle You Need They Can Angle Them (on The Inside) Any Way You
Want

Thses are the unitops, all one piece.

I think you are out of luck. That is the down side of Uni-Tops. I am currently going through hell trying to get a set of standard elbow tops. CMI is sticking it to me real good with long delays for my tailpipes. I am not having a good experience with them at all.

I know it sucks, but buy new pipes or start reglassing.