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Aftermarket manifolds that are CARB-legal should not be that rare. I know that DC made headers for D-series engines that were CARB legal on early-90s Civics; I assume someone makes ones that are legal for the VX.
Don't expect any better MPG with a header. They are pretty much all set up to improve flow at high loads and high RPMs, not low RPMs and moderate throttle settings where you drive for MPG. It is possible you will lose a little, but likely that any change will be too small to reliably notice. It is also possible that it will improve things; you will have to test yourself to tell the effect in your particular case.
Any good way to weld up the original part? A good exhaust shop would be able to tell you if it can be done reliably.
-soD
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