Did anyone else have any trouble getting the headers to seal up against the heads? I have a small leak at #8 that I can't get rid of. I originally tried reusing the Fel-Pro gaskets from my other headers (yeah, dumb ), and they leaked bad. I installed the gaskets that came with the headers now, and I am down to a very small leak at #8 that I can barely feel. I have a bad leak where the downpipe was welded to the collector reducer that I'm going to have to weld up myself, since the shop that did it is three hours from me.
Check the bolts your using, the ones that came with the headers were too long, I had to shorten some.
I thought they looked awful long.. but my others were too short for the monster flanges. I just got off the phone with Jamie, and he said that the bolts they were initially sending out were too long, and he thought these were the current ones. They are 1 1/4". They don't feel like they are bottoming out, but I might try a 1" bolt and see what happens. My old bolts were only 3/4", and I can engage a few threads with them, but I don't feel comfortable using them. I am really impressed with the level of service Jamie and his company are providing us. They are definitely standing behind their product.
Mine don't leak.....but then again, I didn't use the bolts that came with them. I used a stainless steel bolt kit.
I had an ARP bolt kit, but like you said, I think they were only 3/4", I used the bolts sent with the headers, and used the ARP washer (the ones that came with the headers were to nasty to use on the ceramic coating) Any bolts that I shortened, I cut almost an 1/8" off them.