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Dear Paulii,
Hope you're well and stay so: you, more than most, know that it is hard to get spare parts!!
Your solution is top-notch!! Is there not some risk that vibrations from flattening the flare on the cat pipe, will damage the honey-comb? I'd strike gently, but still be worried about damaging the cat's interior.
Alternatively, if I grind-down the pipe edge - inside the triangular welded plate's opening - a sealing ring can seat against that opening. I might be able to angle the circumference of the plate opening, using a hand-held grinder. It will be hard, though, to get a uniform angle.
I wonder if this ANSA pipe has been modified. Do you recall having seen an engine pipe, with a fixed-position triangular plate
Thanks again, for the great ideas!!
Yours faithfully,
Spook
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