Take pictures of bad fitment, return for refund, and get a new one.

 

I don't think it's a manufacturing issue. I think it's a me and mechanical force issue. I'm not too keen on banging on the bends so looking for thoughts on alternatives. I may also see if I can disassemble it and try again with some sort of lube.

 

Have you tried attaching the long pipes first and then adding the exhaust tips last? Is there a reason you can’t do it that way. BTW, I have no experience with this job so I don’t know if I’m suggesting the impossible. I’ve just found that in the past, what looks easiest often is nearly impossible in reality.

 

An inch out of place sounds like a way out of tolerance part. Shouldn't need to force something to fit together and might lead to damaging something.

 

I took it apart and followed some tips I found on a Bronco forum. Sanding the joints, a little soapy water, and a bit more force against an immovable object (my basement floor and several layers of carpet scraps) got everything nicely together. The job is done for now, though I'll likely replace the bolts I used to connect the over-axle pipe to the down pipe on the passenger side next time I have the wheels off. I just used what I had in my toolbox.

It was not a manufacturing issue.

 

C'mon if you have to do this
"Sanding the joints, a little soapy water, and a bit more force against an immovable object (my basement floor and several layers of carpet scraps) got everything nicely together. "

I've scrapped parts because of mechanics trying to force stuff and causing damage