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Have the headers and side pipes jet coated.JCL baffels are a insert for the side pipes.Lot of the guys use them insted of the hooker inserts.E-mail me if you want the link to the jcl site.
When I bought my Hookers in 1979 or 1980, the first thing I did was to get some Epoxy Primer with the catalyst and mix the two together. Then it was just a matter of pouring the stuff into the headers and swirling the primer around and around and around until all the inner surfaces were coated. I can't be sure of the areas I couldn't see, but after 20 years, they still haven't rusted through. There is some rust on the tubes nearest the ground, under the car, but it isn't too bad. That is probably due to rocks and stuff that hit the chrome as you drive. They get "sandblasted"....so to speak. The set of headers I had before these last ones only lasted about seven or eight years because I didn't prime the inside walls.
What brand of epoxy primer would stand up to that kind of heat? I was thinking of sraying some high temp ceramic paint into the headers to coat the insides. Good up to 1500 deg. I have some hookers with small rust holes on the bottom of the collector areas. Has anyone patched this area by welding, brazing, high temp epoxy patch, etc.?
I can't remember the brand of primer because it was so long ago, but I do seem to remember it was kind of light green. It wasn't zinc chromate green, but more pastel. For all I know, the stuff might be burned away by now but the headers are still doin' fine.