Images of stepped washers for the manifolds<

Along with the supercharger kit, I also bought the header from HP. Where the mounting flanges of the intake manifold are the same thickness as stock, the mounting flanges for the header are about 0.2" thicker. The original flat washers will not work in this situation. Stepped washers are not easily available, at least I don't know where to get them, and did not come with the kit, so I had to make my own.

The first attempt involved going to the local hardware store in search of 1/2" washers that were 0.2" thick that I could cut in half. I wasn't able to find any, but I was able to find washers that were 0.1" thick. At first I made them by simply gluing the small washers to the large ones with "liquid steel". They only needed to hold long enough to bolt everything together, then the clamping force would hold them all together.

Due to an impressive series of stupid mistakes, compounded by bad luck, I've had the unit off of the car more times than I care to count. A friend was able to do some simple tack welds on them that held everything together a lot better. At least they didn't fall apart when I dropped them trying to install them. I did end up needing to do a little bit of grinding on them to get them to fit in the narrow spaces when installing them.