Yes I realize they have to be able to expand and contract, especially stainless. The old ones were David Lotts headers that he sold. Some of it was probably my fault, they did see 16-1800* regularly going down the track. After 8 or 9 hooks they were trashed.
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Do you have a picture of the setup? The problem is not the material, nor the strength of the material. A stainless header will see your aluminum pistons in the bottom of hell before failure if designed correctly.
I wonder what the environment in a top fuel header is like for instance. We are not outside the scope of a SS header.
Where did you have all the bellows and/or slip joints placed at in the setup that failed?
A picture would allow us to possibly see any design problems.
To cut to the chase....
If you want an actual solution, explain how it was set up, or preferably show a picture of the old setup. Within 5 seconds it can be determined if the layout and design was at fault or if you just got a set of headers made out of copy paper, or held together with bubblegum, because a SS header will go down the track no problem on a diesel engine for a few short seconds.
Or... just assume headers can't handle the extreme environment you operate in and live with a lack of solution for your need. Which is silly.
That's just my take.