i taped an episode of Muscle Car on Spike a couple weeks ago where the guy was building some headers from scratch. he was using "alignment rings" (as he called'em) but i can't find them anywhere,i looked at Summit and Speedway and all the header websites,but i came up with nothing...
I've seen them written about somewhere years ago, they also have a raised area in the center, I guess if you're good with the torch you use the ring as the filler?
they look like this (gosh, why didn't yorgatron google header alignment rings?) http://store.summitracing.com/egnsearch.asp?N=400390+316412&autoview=sku
Often you can weld stainless steel and other piping systems by using a consumable insert, often called an EB insert. You weld the root pass by fusing the consumable insert, which melts and flows to form a root pass of good geometry. http://www.thefabricator.com/AluminumWelding/AluminumWelding_Article.cfm?ID=1173
This sounds like Gadgett of the Week. Many, many sets of Hand built Headers under my Belt and didn't know I needed them. What will they think of next to bleed you of more $$$$ ? The Wizzard
L.O.L. Not really Skilled just had a Grate Teacher (Russ Meeks) on my First set. Plus I really enjoy building them. If I can do it, anyone can. The Wizzard