Headers hitting idler arm

MoparLeo said
Remember that TTI does build an excellent product. But they don't build the car or the engine or the mounts and they don't install them. That leaves a lot of variables on the table. TTI does give you the dimension charts for the different chassis models and engine sizes for you to verify Before you install their product. It is in the directions and on their website.
Cutting, grinding, washers yada, yada, yada means something is not right, it doesn't mean you have to do those things for the product to fit unless it was defective in which case that is what the warranty is for.
Footnote #39

I agree. I really don't think it's the headers that are causing the problem. I suspect something related to the big block swap or an inconsistency with quality control as @Furious65 mentioned. Someone on FEBO suggested contacting TTI and initially I agreed, but I don't think that's necessary.

Dartswinger70 said
Can you loosen the header bolts and see if you can adjust the header where you need it to be? you probably only need 3/8 to 1/2 inch. You probably have to wrench it into position, and have someone cinch down the bolts...

Unfortunately that's not a possibility, my heads have studs and the tolerances for the holes in the header flanges are quite tight. Not much wiggle room.