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Has anyone had luck adapting an oem s2000 header, pr other oem header to you Duratec? With my 442 chassis I am not sure any other header might be adapted short of going full custom

The obvious choices would be Caterham ($$$$!!!), a header for a focus or escape as it will be pointing the right direction and the primaries could be extended through the side of the bonnet, or use the ford manifold that is clean and much like a shorty header. Just clean and ceramic coat, then add a mandrel elbow at the head pipe to bring the exhaust outboard of the frame. New manifolds around under $100. It will also help keep the heat down under the bonnet compared to a thin walled header with the same finish.

A long tube header with the same bore spacing could be used with a new flange to fit the duratec and the primaries would need to be extended anyway. A long tube header for the older lima 2.3l might work.

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12

I guess that depends how I want to approach the exhaust in general, I could certainly go that route, But this is part of the car where I expect to spend some money to have a header and exhaust I like. Or whatever I have energy for when it comes up on the to do list

Designing and building your own header can be a very rewarding side project, one that you will be proud of every time you look at it.

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Midlana book: Build this mid-engine Locost!, http://midlana.com/stuff/book/
Kimini book: Designing mid-engine cars using FWD drivetrains
Both available from https://www.lulu.com/

I was looking at 1.5" ID 304 stainless bends and sections. I saw some on AliExpress that had an attractive price, but listed 1.5" OD so I need to figure that out before thinking about that route. I have a Manifold plate already and have been getting an Idea of what is involved, and I may as well 3d print some mock up tubes or bends to plan it out. I am open to any suggestions on where to get stainless sections or J bends.

They have 38mm and 45mm OD tubing with a 1.5" wall. that would mean a small stepdown in size of 2.5mm if using the 38mm tubing, or a step up of about 5mm in diameter over my port size. Obviously so close to the port you want a smooth transition into the primarys. Might have to pay for pipes sized for ID

Tubing is always measured on the OD. Pipe is always measured on the ID. Tubing slightly too small for the port is fine, as it can be tacked in place and, using a brass drift, stretched slightly to reach out the the flange walls. Oh, and anything from AliExpress will most likely be metric, regardless of size claims.

_________________
Midlana book: Build this mid-engine Locost!, http://midlana.com/stuff/book/
Kimini book: Designing mid-engine cars using FWD drivetrains
Both available from https://www.lulu.com/