Hi Randy,
The cast iron headers you need are 1965 and 1966 specific. Other years WILL NOT fit. The part numbers are C5AE-9430-H & C5AE-9431-G. These are the 427 headers and will fit 390 & 428 heads with the 8 bolt pattern. I have them on my 1966 7 Litre (4 speed car) and as you suspect, they are a tight fit in particular around the steering box. I do have power steering as well. Just to put my mind at ease, I shimmed up 5/16" under my motor mounts. The clearances looked better that way.
I was fortunate to find an NOS set of these 3 years ago for about $1400. They do show up on eBay about once a year or so, but people don't give them away. I've seen crappy sets go for $800 or $900. If originality isn't a factor, tube headers are cheaper, lighter, and won't crack at the flanges as these can be prone to doing.
Shoot me an email and I'll send you pics. Charlie
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