Header bolt size on 440s

As stated above, it is a good idea to run a tap into each hole to clean out the threads. If you are running 3/8" flanges on those headers, than yes you need 1" UHL bolts. If they are cheaper headers with thinner flanges, you can use 7/8". I prefer to run the longest I can as long as they don't bottom out.
I always use the longest bolts possible that won`t bottom out. especially on alum heads.