Maybe this is the culprit... this isn't the best picture, but you can sort of see the spacing.....
I checked the bottom where the header slips into the side pipe and it was on there fine. There may be some spacing between the two, but they're still overlapping.
UPDATE:
So I get to figure out if my exhaust manifold is 1-3/8" W x 2-1/32" H or 1-5/6" W x 2" H.... really? Seems to be a lot of soot at the block/header and a bit of space so I'm guessing it's there, according to the pic. Where the header meets the side pipe it has significant overlap and it looks pretty clean. I noticed some spacing where they meet up, but I don't know how snug their mating is supposed to be.
Can't believe I have to take the header off just to measure the hole size for such a minimal difference.
Guess I'm looking at getting one of these two depending on what I measure.
http://catalog.remflex.com/PhotoGall...uctCode=RF3009