Im building a header for my zx10 and I ordered some standard 2 bolt flanges but they are way too thick. I can make them work but I dont have much thread left on the studs. I heave searched google and all of the Suppliers listed in the sticky and can not find what I am looking for. The tubing it 1.75 and I am looking for some stamped 2 bolt flanges similar to these pictured.

Untitled by 1upmoto, on Flickr

 

How much thinner do they need to be?

Doesn't look like you have any room to give without making the flange weaker . . . every thread on a 1.25mm pitch is ~.049". It looks like you would need to thin out 1/2 of the flange to only get 1 more thread engaged on the stud.

 

Well I think I am just going to order some longer studs, here is what I am working with.

Untitled by 1upmoto, on Flickr

 

Longer studs would be the best bet.

 

are the thicker flanges radiused on the inside diameter like the original flanges? if not they might cause sealing issues on the flared tubing....