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I'm not sure what kind of headers you have but a friend of mine was having real problems with his 67 GTX blowing header gaskets. WHat a racket it makes too, sounds like something much more serious to untrained ears, but anyways this is what he did. He has hooker comps or something like that. From front to back you have the first pipe, then two pipes together (second and third) and then fourth pipe. We carefully took a sawzall (however u spell that) and cut the headers inbetween the first and second, and then inbetween the third and fourth. This allows the pressure to be distributed more evenly on the sealing surfaces. Some headers come this way. This worked for longer than before, about a week, as he was blowing them daily. I think he is currently using a copper gasket. The trick is too retourque the bolts daily for two weeks or so the copper gasket especially collapses alittle bit. Since the copper gaskets he hasn't blown even one. If this is confusing i can try to explain again. Hope this helps.
are/were you using std. header bolts? & if so, did they back out or become loose over time???
If so then i'de use a set of stage 8 locking header bolts. We have used them always and nobody I know has had a leaking header gasket, assuming the header surface is not warped and both surfaces are clean, etc when installing them.
You can also go further and use some red high temp RTV sealer around the exhaust ports for the "ultimate" seal.
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