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Oldsmo, I know what you mean that those boots are pretty good size. We buy that wire by the roll and use it on all new engines. One thing before you get too carried away though. On my engine header and plug clearane is extremely tight. It is a struggle to even get the boot over the tip of the plug let alone pushed all the way on until you feel the "click" of the connector. So one thing, are you sure that the boots fully seated into the connector? There should be very little of the plug porcelain showing once it's seated home. On three cylinders I have maybe .080 clearance between the plug boot and the header. Over the past year I have not had any issues with the boot burning. The boots seem to take a lot more heat than say a Taylor 409.
I know the AFR's can be tight with some header combos but I'm wondering if it's really an issue or not, I have always used Hedman or Stahl headers on an application like this so I don't know really how much room you have. Neither of these style headers though have posed a need for shorty plugs.
As for a shorty plug Accel makes some although not ever using them I don't know how they cross versus what your currently using. They would be an option for you though.
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