Stainless header flange
#2
I would say if you cant find any pre made look for a local shop with a cnc plasma cutter or water jet and they can scan some gaskets for you and cut whatever thickness you would need. Plenty of these shops around my area ( I work with a guy that does this on the side, I could refer you if you like) so I don't think you'd have a problem finding someone to do it for a reasonable price. Heck, have him cut a few sets and sell them to recoup your cost.
#4
Assuming they are talking about Oldsmobile "big block" (and not Chevy), they are the same on every Olds V8 built from 1964-1985. Only the 1985-1990 307s with the 7A heads had differently shaped ports.
#5
#7
#9
Sorry, but that sounds like a whole lot of work for very little benefit. Even "shorty" headers take up more room that cast manifolds. The individual pipes and resulting bends make what you are suggesting extremely difficult if not impossible. Look at the crappy welded tubular manifolds used on the 307s from the late 1980s. They are ugly and are the worst-flowing manifolds ever offered on an Olds motor. Cutting and welding the exhaust pipes to fit new custom-built headers will by far be the easiest part of what you propose to do.
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