Way O.T. chevy truck exhaust dilemma

Problem is, I have not been able to fit a pipe to make the transition through the transfer case, cross member area and line up the exh. pipe collector flange to the header flange correctly. The bottom of the collector flange has a 1/2" gap, but is flush at top. I can align the pipe, just that the flange has a gap on the bottom, having trouble figring out where to make the bend to correct it.

The ingenious idiot that I am and I have to laugh about it thinking back, I first took a piece of flex pipe, fit it in there until it looked right, held the bend, strapped it to a board, and took it to the muffler shop down the street, they bent up a piece, close but no cigar. Next I offset the collector on the pipe while it was on there, used the flex I had there in the joint to make a good connection, it was flush with the header flange, I then made a pencil mark around the pipe and had it welded on to that mark, and it was still no good when I fit the pipe in there again, so the trial and error method is not working well on this. Was getting irritated, so I thought it best to leave it for another day. So darned close, but no way it will bolt up properly with that gap at the bottom.

I recall years ago, I had bought the first set of headers and dual exhaust kit as one kit and the pipe I needed for the right side by the transfer case was in the kit, and already bent correctly, and fit in there with no problem. Somewhere, someone was fabricating this pipe at one time, there should be a bending card or fabrication sheet for it somewhere, even though it's not stock for the truck. The 73-87 K-10 trucks were abundant, and so were the performance exhaust kits for these, does anyone know where to start looking ? The auto parts stores and muffler shops don't seem to help, and I've looked on the net through applicable exhaust diagrams by flowmaster, walker etc. no luck finding anything yet.

Not having any clue about pipe bending, not sure how to make something work, it's always off, close, but still off. I'd hate to go back to a stock exhaust, bought and installed a new set of headers, wish the old pipe did not disintegrate.

Anyone else here deal with these old chevy trucks and this pipe by the transfer case ? Looking for alternative ideas or suggestions.

I'm trying to stay along the outside of the t-case, above the cross member, it's got flowmaster headers on it, nothing stock, which I am sure would have been easier to deal with as it's listed in the walker and other books showing exhaust systems for these. It's actually a simple bend, just something off a little.

I like the PVC idea, and Walt's too, I had contemplated the wire thing, but figured the flex pipe would have done it for a template. Even with snow coming, I had to set it aside, and try again with a clear head, once I get frustrated hard to think right. Just on pipe with a collector on one end, should pass through above the cross member, with 2 slight bends, both like 20 degrees that offset the pipe, then it's straight to the back. I've run this sucker with open headers, sounds good, but the fumes get into the cab, hard to deal with that. I may have to get it fired up and bring it to them, the heck with it, only 1/4 mile down the road.

I'll bet you had some fun with that one set up like you say, only thing I can recall when lifted was the u-joints wearing out, forget how that was dealt with, something to do with the angle of the shafts.

It's a stone's throw away, be my luck getting caught if I chanced bringing it in there, off road, no brakes either, but if it was on their lift, it would probably be easier to fit. It's a tight fit, but has enough room with the correct bend as I recall, wish I had the old pipe now !

Thank God I live where I do!