Steve hope all is good Figured I would chime in here I would imagine you got most of your questions answered but headers are a real pain if you don't get the right ones and keeping the bolts tight are another thing also. Do you ever go to Summitracing.com, they have a few choices for the header bolts, the alien head s are good but they also sell bolts with a 12 point head and other locking type bolts. Hope this helps.
http://www.summitracing.com/search?S...header%20bolts
The stock headers are also a pain on my 95 K2500 we had to use a pry bar to get the holes to align.
Here are a couple of pix of the cermac coated headers I bought from Summit
