I still think the oval pipe transition will save you a ton of work and you don't compromise any tube size.

The oval pipe will help AFTER the collector, but the clearence issue AT the collector will stiff be there... that the part I'm concerned about

I also thought of doing the exhaust "band clamp" style connection at the header rather than the big "triangular" flange...much lower profile, but not sure how well it would seal

a vband will seal better than a 3 bolt. problem is they are damn expensive! ive got some tight spots on my exhaust as well, so im interested to hear some more opinions.

I'd just have a complete custom set of headers built....

There's this guy up in the Vancouver, WA area that is 'ok' talent wise...

:rofl:

Here's a set from Stan's Headers (Auburn, WA) for the 5.7 hemi (assume they're the same? flange as the 6.1)

http://www.stans-headers.com/Photos/357.jpg

Talk to a good muffler shop and take pictures with you to show them what you want. They should be able to heat the tubes till red hot and gently bend it down. They would be heating the whole bend area.

I can't see pictures of his 6.1 hemi headers that are built for the 300C (SRT8) but I can tell you this about these guys.

I cut and mocked up a couple of tubes for a special set of headers in a car I was doing. Took the header down and showed it to Stan... I wanted him to mandrel bend the two tubes for me and he says "just a minute". He goes back into the shop and comes out with a header that is one of their mock up sets.. and says - try this. It fit perfectly. Turns out it was the mock up for the Art Morrison 62 Corvette/Morrison chassis... which is now a stock part number.

The amazing part was that this guy could look at a pile of spaghetti and recognize a similar pile that would work. :woot:

Charley --

Is my coffee ready?
:D

I ran into issues with my exhaust kit and Long tube headers that I bought.
I spent alot of money on the LT headers and exhaust kit. This kit was supposed to fit and bolt in. Now, knowing what I have learned. It would have been cheaper for me to pay Tim to build everything from scratch.
We had to modify everything from Headers all the way back.

I got 2 brand new stainless mufflers, I can give you a good deal on.