These headers are designed for the roundy round guys. They are a basic design common to Schoenfeld and Dynatech. These headers can be had for as little as 150 bucks or so in mild steel. With these, the headers will protrude about 1 1/2 or 2 inch into and 2-3 inch from the front of the AC box where the aluminum tube comes into the box for the evaporator. While all this is on the one half of the box, it was more then I wanted to play around with. The pictures do not give a real accurate reference. There is a easy hands width between the top of the tubes and the box. I may try to use some header wrap here since they are basically paired in this area. Over all, there are about 4 hours in this modification including cutting, fitting and throwing it back in the car for one final test fit before purging and final welding.
For some reason, there is a lack of affordable single piece 1 3/4 inch headers on the market for these cars despite being such a popular build. Additionally, the ones available do not have 3 1/2 inch collectors like these.