That bites about your experience with Borla...but it is actually the first time i have ever even heard of a Borla problem. I have run their stuff on several different cars and never had a prob. All of it was first class made/material/fit. The clamp on fittings, for me, are a temporary fix untill I get the vehicle to my exhaust shop to weld the joints. I would go up the ladder at Borla and complain until something was done....
BTW, wanna sell the old,no-fitting headers cheap?

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Had-94,96,98,99 Cobra Stang,99 Navigator,03 Expy, 05 H2
Have-08 Titan C/C,06 GCSRT-425FTLB & AWD, other junk..
Want-08 Viper, 06 M5