http://www.fourwheeler.com/techartic..._long_headers/

 

Thank you CanadianWR450 for posting this article. I remember reading that before and is part of the information that I have come across in the past that causes me to think the way I do about headers.

 

I would take this article with a grain of salt though since they can't provide numbers from below 3,000 RPM

 

I still say gears are going to get you a bunch more low end then any header...

 

That is very true but gears cost at least twice as much

 

Gears and a programmer would be your best bet. Then if you feel you want more power, go with the headers. I agree with Canadian their. If you wanted the power at the top end of the power band, I would suggest working with the motor first, then the gears. Gearing is the best way to multiply torque at low RPM's. Look at semi's they go maybe 500 RPM between gears and only have on average 150-200 HP but thousands of ft/lbs of torque behind them. That is all due to the gearing in the transmissions and rear differentials. 'The torque you are looking for is best sought after in gears.

 

For the biggest low end torque gains a cam with the proper grind would be the best by far. It's basically the stock cam in the 5.7 that determines where the Hemi makes it's power. But cam swaps are not cheap and one with a profile to make significant difference in the low end would also require a custom tune. When Marty was still at KRC, he offered his 210 cam with an optional custom -4* grind that would make you think you were in a diesel truck when you touched the accelerator.

Second and a lot easier would be to re-gear even though technically gearing doesn't change a thing in regards to HP or Torque they get the RPMs up higher at a given speed so that you are up in the higher torque band sooner.

Programmer is also a decent choice and it gives other benefits as well...

 

Also very true. It's going to come down to how much gains you want, compared to how much $$ you have.
Here is my advise for the OP though - Do a programmer first, it is relatively low cost (compared to other options), and it did make a noticeable difference for me at least. Not so much in power (although it was stronger..but not "earth shattering" gains), as in tranny and shifting improvements (SuperChips). This will help out with your gear searching issues you mentioned (all the other features are bonus, like tire size setting, disable MDS, TPMS...etc).
Might be good enough for you right there and you can call it a day. Might make it at least bearable while you save money for gears... MY next step was gears, and in my case with going to 285/75 17 Toyo MT's, and with what I do with the truck, it made it a whole new truck. Expensive, yes. As expensive as doing whatever else you may do to get same results? No.
Not saying go bankrupt, or borrow money to do it, but if you CAN do it, that is the cheapest path to the biggest gains in my opinion.