spshutlz and wistful,
Thanks for the input. We will look into the 3rd cylinder O2 sensor bung. The price that you mentioned is what we have in mind. The locking nuts/bolts are another item we will investigate. What do you think about a header protector plate, similar to a differential guard/protector? This would be optional most likely though as not everybody else would want it.
We are looking into a "heat retention" coating. Actually, what the majority of the coatings are that you buy are oxidation inhibitor coatings (stop rust). We want to make sure the header lasts as long as possible. By the way, the really good heat retention coatings do nothing to inhibit oxidation (rust) and will add about $250 to the cost of it. They are a modified zirconia base material and not a ceramic/aluminum metal matrix which is normally sold. This is keeping me up late at night, trying to figure out how much of these items we can include and still keep the cost reasonable. Heck, I thought marriage was tough!
To be honest with you, it is extremely difficult to work with stainless and titanium to achieve the shapes required to produce an acceptable level of power and still keep the cost down to what everybody will accept. When you look at some of the other designs that have been executed and sold, it becomes obvious that the engineering goals were to get a bit of power and make sure they offered all of the hyped up features that would sell the header. I'll try to get the header article up this week to better explain our stance on the issues we have to confront.
Our goals currently are to get you the largest power gain, make sure you have a header that won't rust out on you or break and make sure you won't have a CEL a few miles down the road.
Cheers,
Ethan Fisher
Cobb Tuning