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The difference in the materials between the collector & primaries are my concern. Mild runners with stainless collectors tend to leak due to the differences in thermal expansion.

We do --- a about a handful of different headers (less then 10) for certain resellers/tuner shops under their brand names. If it's something you are interested in producing, I don't see why we couldn't get you started. If you want a one off, that's possible also but it wont be production bent -...

The metal cats we use/sell are 8"x4" in 3" inlet diameter.

For 309 on a mig, use a tri-mix. For 309 on a tig, use pure argon. For the ultimate look/strength mild/stainless on a tig, use 347.

1" DOM is very popular.

The best bet would be to build a temporary jig locating the head flange in reference to the outlet flange, then 1 by 1 removing each runner and welding them up. You may have slight leaking issues with that collector in high boost situations.

We are a new vendor to Lextreme. We are a CNC mandrel bending company specialising is OE replacement exhaust systems. Racing Solutions is our online store offering wholesale direct pricing on some of our DIY bend products. Please let us know if you need something that isn't listed. Our web...

Splayed or parallel?

Try 14 gauge aluminized mild steel, I've never seen it fail even under the most demanding apps on crossovers. You might also try the dual lined flexes, they have an internal lock liner that makes them *near* smooth inside as opposed to the standard highly restrictive ribbed flexes.

Most of the header repairs Ive ever done were on stainless wrapped headers in turbo apps. I havent seen problems with wrapping or coating in non turbo apps either way.

We've built a lot of x-pipes. We always run them infront of the cats. I highly prefer the double y-pipe merge collector vs any of the other iterations available. Here's an xpipe for an exhaust we made for the twin turbo 350z, it made 22hp/14tq more then the true dual 3" system it replaced...