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I talked to Reg at Backdraft today. He is aware of the problem and has taken some measures on the new cars to make the headers a little more shade tree mechanic friendly. He is having the factory rework the flanges so the holes will align and the welds are now on the inside of the pipe so they won't protrude into the bolt holes. Should make a world of difference. I'ld be interested to know what you think when you install the new headers. By the way, Reg sounds like a stand up guy to me. I was a lot happier after talking to him.
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