The best way to deal with the casting plug is have them welded shut (Heli-Arc? or something like that) using an aluminum plug.
It seems that the three big things I need to do to use an Offy header is: Grinding to fit w/ Fenton, Heat Plate, and Welding the Casting Plugs.
So, the brain says - I wonder if they could weld a fitting were the casting plug is and just use a plain plate for the middle for heating. I guess I better get my order in for the intake manifold and find out.
I don't know if it is hair brain or not -- I starting to think hair-brain as I doubt I can improve on Offy's method and the clearance room looks really tight.
Why water over exhaust for me: The toy will not come out in winter, so quick heating is not a necessity. Also, the argument that the hot water can perhaps lower the temp of the manifold on those dreadfully hot humid Iowa Summer Days - Whether it is true or not, I am not sure.
The counter point of using heat from the exhaust manifolds, which would eliminates a potential messy accident also weighs on me. It is a winter projects, so I have months to waffle back and forth!!!
This is one of the benefits of owning, I get to research, tinker, and start over if I do not like the results
