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Yup - I'm at it again. 242 w/5.0L Ford using the Ford Racing shorties. Trying to create enough room for 2.5" duals without hammering up the sheet metal under there. I'm gonna re-weld the flange on the ball of the header - shift it by about 9 degrees. That will allow plenty of clearance for the ball socket studs/nuts next to the frame rail.
Here's the question - I believe we can snuggle a 2.5" pipe up there IF I cut off the top and bottom, inside corners (close to where the starter hump in the bell housing is) of the metal structural bracket that holds the rear control arm bushing. Hopefully you know which piece I'm speaking of. It has two corners that protrude into the area where you'd like to run the passenger side head pipe. It looks to me like no harm would come from that, but I'd like your opinions/experience. Any reason I can't trim that bracket a bit?
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