I just replaced my manifolds with headers. The passenger side has a broken bolt in the head (at the front) that I couldn't get out. I put it all back together with fiber gaskets and high temp. silicone to fill the gap, hoping that things will stay together while I figure things out.
Heat really is an issue. My solution was to use some Thermo Tec header blankets. They are AWESOME!!!! You should wrap the headers before you install, though. Just do a real close wrap and tie off with stainless steel zip ties or with some stainless wire.
I also started replacing the rest of the rusted out exhaust. So far, I have just gotten the h-pipe replaced and will change out the mufflers when things get a little sunnier in late spring or early summer.
I am assuming you don't have smog testing concerns there in Texas, or do you?
Jose