Mark,
That was exactly why I needed to get creative. This took awhile to do (melted 1 Dremel tool in the process), but the alternative was unthinkable in terms of disassembly time. Plus - I'm not the welder you are. By the way, I took the coward's way out on my pivoting rear hatch. Wound up cutting away some of the rear hatch (under the license plate area) together with turning my rear hatch pivot holes into pivot 'slots'. Now to open my rear hatch (and clear my new exhaust system) I raise the hatch a few degrees to clear the firewall, then slide the cover backward a couple of inches. It's just enough to allow the end of the exhaust pipe to safely enter the area I cut away and allows the hatch to be opened up fully. The one problem it doesn't solve is if I want to allow the engine to continue to run, since the hot exhaust gasses would blow directly against the inside of my cover and probably bubble my exterior paint. I'm still happy though with my 90% solution. Thanks for all your help!
your RSK/RS60 brother,
John