Is there a way to get the Clifford headers and the stock manifold to seal better? They are different thicknesses and the old ones had a triangle washer that bridged the gap between the two (equal thickness) bosses.
A simple washer and bolt doesn't seem to be adequate. Any help would be appreciated!

What is the difference in the thickness? All the Clifford headers I have seen the flange is 1/2 inch. That was one of the nice things about Cliffords. Other header manufactures used thinner flanges. If there is just a small difference, you can put a little bit of weld, on either the flange or the side of the washer that contacts the low flange. If there is a large difference, try a washer, or nut between the triangle washer and the flange.

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Charrlie_S
65 Valiant 100 2dr post 170 turbo
66 Valiant Signet 170 nitrous
64 Valiant Signet
64 Valiant 4dr 170
64 Valiant 4dr 225

I too had this problem when I installed my headers. I took a handful of washers and cut them in half, then placed them behind the little triangle washer. It is a tedious job but the only way I have discovered to do it.

After a few hours of running I re-torqued them a couple of times and have not had a problem since. Have had this set up now for about 3 momonths

From memory when I fitted headers and a four barrel manifold to my Pacer I had a smillar sort of problem. My intake flange was thicker than my header flange. In the end I think I bought two intake gaskets and cut out the exhaust flange parts of the gasket, then contact glued them on top of the exhaust flange position of the first gasket.
This meant that I ended up with a single thickness intake and double thickness exhaust gasket all in one. This moved my header flange out further so it lined up better with the intake.
Kitch

I remember reading that the header/exhaust flanges should be thicker because they require more pressure to seal than the intake. I cant remember where i read this though...it makes sense though because you can only torque those suckers down so tight and if the exhaust flange was thicker, it would recieve more pressure than the intake.

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Drive it like its stolen, and be glad im not YOUR son...