You are asking Bill, but he said talk to me, so I'll chime in.
For whatever reason, it appears that no header manufacturer can get their product to truly fit. I have the Cadillac of headers, L&L's, that cost over $600, and they don't fit. In fact, the driver's side header is against the frame on Big Blue. So, when you give the engine some gas and it torques to the right the header comes off the frame - until you let off and it slams back against the frame.
I don't know that ALL headers don't fit, but I've read too many stories about them not fitting that I'm starting to believe that's the case. However, other than hitting the frame, mine are fine. L&L's have a very thick 1/2" flange, and that seems to cure the perennial leakage problem that most headers have. And I don't have a problem getting to the starter with them either.
Gary, AKA "Gary fellow":
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Dad's: '81 F150 Ranger XLT 4x4: Down for restomod: Full-roller "stroked 351M" w/Trick Flow heads & intake, EEC-V SEFI/E4OD/3.50 gears w/Kevlar clutches
Blue: 2015 F150 Platinum 4x4 SuperCrew wearing Blue Jeans & sporting a 3.5L EB & Max Tow
Big Blue: 1985 F250HD 4x4: 460/ZF5/3.55's, D60 w/Ox locker & 10.25 Sterling/Trutrac, Blue Top & Borgeson, & EEC-V MAF/SEFI