I truely feel for you Jeff. I guess I'm one of the only "lucky" ones that got one of those headers that turned out like it was supose to turn out....
Mine had to go back once for a "adjustment", but after that, it turned out really nice.
I had it jethot coated, and ran the piss out of it with no warpage, or leakage what so ever.
It was well worth my money spent, due to the fact I felt a huge gain in my power band with it.
I hope you end up with one that makes you happy. Its a pisser when you put so much time and money into a part, just to have to toss it....
Good luck buddy!!
j.