Everything you describe is normal stuff with any aftermarket part. We used to call it "Hot Rodding". Had a student this semester spend over 5 hours grinding/drilling/filing an Edelbrock Performer RPM intake to fit a set of Speedmaster heads. All 8 mounting holes needed modification. The lower flange of the intake needed clearance between the valley cover as well as the cover itself. The top of the intake needed softening and reshaping top clear the valve cover rail. On the plus side, I much prefer having an intake with lots of material to possibly remove than having to weld up and shape in intake. At the typical shop rate of $125.00 an hour, he had $625.00 of labor fitting a $250.00 manifold. That is typical.
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