[keezling]

One thing I did on some problem headers way back when was to cut the flanges between the pipes so they bolted on independent of each other and conformed to the head surface. Gaskets are at best a band aid. If the flanges aren't flat or have weld blobs sticking up it will always be a problem. I hate exhaust leaks, best wishes on success for you. (Ford did run factory tube headers with very thick flanges, like 1\2" thick)