I spoke with a guy here in pa. Said he had the same problem with his headers . He sent them back to Dougs and they found the pipes where bent wrong and sent him a new set of headers. But they had told him to beat in the headers first. he refused saying at the coast of them was to much to not have them fit right. He also figured it would void any warranty on them. I really do feel sorry for you with all the problems. I have run out of advise for you. Sorry mike. If I think of anything else that will help I'll let you know. Good Luck