I feel your pain. I bought a set of 2 1/8" Hookers for my 64 Belvedere. The motor is on a plate and still couldn't get the #1 & #5 tubes to clear the steering shaft & the left torsion bar. I had to cut and rotate the #1 tube. I flattened #5 and may cut it out and rotate it as well. I agree its all part of Hot Rodding. However I don't believe a new set of $700 (uncoated) headers should need 3-4 hours work to fit.
Good Luck Doug