Advice on navigating header clearance issues.
When installing headers in our A body cars, the first thing I do is make sure the mounts (engine & trans) are in very good shape. From there, leave all of the bolts finger tight and then move everything around until it finds it's home. With headers, it's a time and labor intensive job that requires a LOT of patience. As stated, denting the tubes should be the VERY last resort. A friend and I installed a set of Doug's headers in his 72 Duster 340 4 speed car. Each time frustration tried to take over, we walked away. It took us 4 days to finally get everything in it's respective place without resorting to dinging up the tubes.