Well guys.. this thread is essentially dead. While we havent abandoned this design, its been moved to the back burner in favor of something else. I was by the fab shop today and they had just about completed the passenger side header and Im really happy with what I saw. The driver side header should be a piece of cake as they already built a really nice merge collector for it. They told me barring any complications, they should have the headers done next week.
As these were built on a car, we havent had any fitment issues with downpipe clearance so as soon as they finish up, hopefully we can move right to production. The headers are being built around a 3.5 inch downpipe and so far, clearance is okay. Im going to move straight to a 4 bolt design next that relocates the turbo and does some cool stuff that I havent seen on any Buick headers before.
Im going to try to slide back down to the shop and snap a photo of the PS header tomorrow. They should be finished welding it.. they had it mostly tacked together today.
Thanks to Jason Cramer for getting the flanges out so quickly for us. The fab shop knocked out the passenger side header in less than a week once they had all the flanges, etc.