Re: Mechanic cut frame to fit headers, how bad is it?
I would get in there with a die grinder and get rid of the drill hole and then a make a plate 3/16" contoured as needed to allow room for the header. Butt weld it in and grind flush.
As shown above it would of been much better to pull the header and and die grind the frame a bit until you had good clearance.
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