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Just wondering if anyone else has had to cut a small notch in the frame on the passenger side to keep the header from rubbing. A few years back when I installed headers, I noticed the header was very close to the frame, but not touching it. I used a small grinding wheel and matched the size and shape to the factory cut-out on the drivers side frame. I hear the Mopar guys when they have clearance issues simply heat-up the headers and hammer flat spots on them reducing diameter and restricting flow.
on my 78 f250 4x4, I would have had to notch the frame for hooker headers. But I sent them back and got a set of headmans, and they fit fine without notching. My '73 F100 2wd with a 428, didnt require notching on the set of headmans I had.
ive seen some headers with the dents put in them to clear the frame. i dont think they hurt performance that much, at least not on a street car. they modify the headers so if they want to go back to stock they dont have a nasty cut in their frame