Krazykuda...
Sounds to me that he has a different year k-member and had different mounts than would have been used...so maybe its that combo that messed things up...or maybe the original headers were waaaaaaay wrong. Or, again, maybe it was a combination.
From the sounds of it, Solracmopar didnt call Dougs when he FIRST had the issue (or did you Solracmopar?) but waited til after he smashed them. Had he sent the first ones back and had the same result the second time then he would have known it was his car setup (since Doug's is known for having excellent fit).
Solracmopar, did you try fitting the headers with the old "sandwich" mounts you tried the first time (that would verify if it was the headers or not) or did you just install the new taller mounts first? I am guessing the latter, right?
So now we can never know if it was Doug's fault or your car's setup.