I have mine pretty close, about 3/8" on all sides w/ 4x4 headers (jet hotted). 15,000 miles, no problems w/ paint. However, you'll need solid or poly mounts to run them that close w/o hitting under acceleration.
Not that much. I have one of the first sets of 4x4 headers. They've changed jigs at least twice since mine were built.
One pipe was too far forward and too high. THe other was too far to the rear, and too low. I was able to straighten out the high/low business by tilting the engine just a wee bit. I had to trim the cutouts to get the correct front/back clearance. Nothing was off by more than 3/8-1/2" though.
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