Tearing apart hemi 5.7, machine work worth it?

There are a few different options with exhaust for the swap. I believe the easiest fit variety are the truck manifolds (maybe Jeep, I can't remember), but I believe they dump pretty close to the firewall. They offer the best clearance near the block though. Some have had luck with the LX car manifolds, but you have to take a bit of a chunk (not real bad) out of the passenger frame rail for clearance. The shorty 6.1 manifolds have come up several times, but I think the main issue with them is the flanges. They're pretty dang big and I think they tend to get into stock steering boxes pretty quick. If you go with an aftermarket K member with rack and pinion your options open up quite a bit though.

6.1 exhaust manifold will also work on the 5.7 if the EGR port in the right head is blocked off.

Also, JBA "shorty" 5.7 headers should fit if the stock 6.1 headers do.

If it were me, & extensive mods weren't in the plan, I would go W/a pre -'09 5.7.

W/stock (pre -'09)head castings milled .030" on the stock rotating assembly you get 10.4:1 CR W/.035" quench.

You can crank the timing to 'em W/O spark knock & srayed mine W/a 175 sot W/O KR until the trans shifted to 4th & even then there was only 4° of spark retard.

You can make 500HP @ the crank (mine made 426 RWHP 460 RWTQ) on a stock rotating 5.7 W/a mild cam, a good set of heads mated to a 6.1 intake manifold, headers, etc.