Success! Cut the pipe lip on the rear exhaust section short with an oscillating tool and metal cutting blade so I could mate the flanges. Next step was finding usable gaskets. The ones included with the magnaflow cat were hot garbage -- much too thin to fill the recess in the flange and also too...
I started this cat replacement job on my 1996 80-series and ran into the same issue with the magnaflows. Anyone else have a good solution for a tight fit on the flange?
Crank with no start SOLVED! I experienced the same problem as OP in my '96 Cruiser --- intermittent starting issues, cranks great and no ignition. Got stranded 2 times and had to call a tow. Getting spark and crank but no ignition. Guess is a fuel pump issue. Had the truck towed to the shop...