virtual dynos
As for virtual dynos, they arent perfect but they do give some very strong guidelines to work with, if its a good program.
The figures I gave you are, of course, flywheel ratings. Differential readings would be somewhat lower, due to parasitic drivetrain losses, as much as 50-70 hp, depending on the drivetrain.
As I said earlier, were I purchasing the headers anew, and didnt have any, I would have opted for the 1 5/8ths primaries, however, you arent being hurt that much on the upper end by the smaller tubes, and since you already have them, thats a major factor in the equation. Im not an engineer or a scientist either, but having been around racing and hot cars for some 40+ years, I have seen a lot of stuff tried and proven as well as tried and going down the toilet. From years of observing and experience as well, I have a good idea what works and what doesnt, but I am far from being an expert on it.
As for the comments about the 1.6 valve being bigger than the 1 1/2 inch primaries, I already covered that with the throat size of the valve seat.
I remember many years ago, scientists saying it was impossible to build a car capable of going the 1/4 mile from a standing start in 8 seconds flat; then 6 seconds, then 5 seconds, and today we have street driven vehicles doing it in 7 seconds.
As a matter of record, there have been many published dyno tests on headers. Probably the best one I ever saw was in Circle Track magazine back in the mid 80's. They did a very comprehensive test of headers of all different sizes of primaries, on a typical test 350 Chevy engine. Power band wise, stock car engines for short track, arent all that dissimilar to hot street engines. You could plainly see in the test where the headers had their most effect with their power curves. While 2 inch headers look awesome and all that stuff, unless youre going to be turning 4000 rpm plus all night long, they would have no advantage over 1 1/2 or 1 5/8ths headers and almost no advantage over 1 3/4 primaries, until you get into the areas of over 7000 rpm +. The 1 1/2 inch headers showed the best power between idle to 5500 rpm. At about 2500 rpm the 1 5/8ths were the same until about 7000, and on and on. The losses using the 1 5/8ths on the lower end vs the 1 1/2 werent that drastic.
But as I said previously, the 1 1/2 inch primaries wont hurt you as bad on top end as 2 inchers will hurt you on your lower end.