Tri Y headers/ starter clearance

About 8 years ago I installed a set of new Tri-Y headers on my '66 289 engine. It has now come time to replace the starter. When I pull the starter out I noticed a huge "dimple" on the starter where it interfered with the header. The starter worked great for 8 years, but now if I go to replace the starter I will have a problem installing it. It seems that when I tightened the header on that side it crushed a portion of the starter where the actuator cover is. The header sealed against the gasket properly. Is this a common problem? Is there another smaller starter I can use without going to the expense of the small hi torque starters ($200.+). Again, it is the small cover on the top of the starter that is hitting. It is a 289 w/ 3 sp. manual trans. Thanks.
 
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On my 67 it is a tight fit and hard as heck to get in and out, but I made it work. The last time I replaced the starter, I noticed that there was variance between the actuator cover on the old unit and the new one. Looking at the pictures on the Autozone website it appears that there are different covers for the auto and manual, which makes sense given the other differences between those starters. I wouldn't be surprised if some remanufactured starters had a universal, roomier cover that protruded further. I heartily recommend taking it out and comparing what's in the car to replacements at a couple of part shops. That is what finally let me figure out the manufacturing flaw that made mine produce a squealing sound.
 
IF you have the 165 tooth flywheel and bell, it sits out about 1/2 inch more than the 157 tooth FW. Also when I replaced my starter this summer, the stores have the Auto and Manual part #s mixed. So be sure to ask for an Automatic starter.

I couldnt get the Manual starter to fit my 66 with T-5. I read about the mix on this site. Traded for an Auto starter and it fit perfect in seconds.
 
"Auto Starter??? But I have a 3 speed Manual trans. I think you may have miss read my original post.

Thanks

Bluepiper, you are misreading Pony66's post. He is saying (I think) that the auto supply place where you bought the starter may be one of those that has the numbers reversed on the auto vs standard transmissions and therefore when you bought your replacement they may have given you the wrong one. He is suggesting you take it back and ask for a starter for an auto and would receive the correct part. Or, just take it back and ask to compare it to the one for an auto and see if it is smaller or larger.