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Hi cuddysounds;
I just went thru a very similar situation with my 745t. The flanges holding the header pipe to the cat pipe simply rusted away and let go. Volvo actually sells a VERY slick split flange(2 piece) that can be assembled onto the flanged pipes and then lined up and everything bolted back together with bolts, nuts and wasshers. Don't forget to get a new donut gasket for between the 2 pipes. Cost for the split flanges was $15 +/- each( I needed 2) and I think the gasket was $11 from Tasca Volvo. Just drove 1 side of car up on ramps, assembled bits, and used a mini grinder with a thin metal cutting wheel to cut off remains of old rusted flange mess. Worked slick as S##T and took about 30 minutes,
Dan
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