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Re: Cast header question
yeah it is going to move up and down, not front to back.
Just a gut feel, I'd want at least 1/2" all around with the flange, donut all in place. And I'd probably go for more than that, if it is hitting when you get it on the road you'll wish you cut more now.
The boxing plate looks like it will be plenty strong even with a hole in it, I don't see anything welded to it nearby. I'd make the corners of the hole as round as possible to avoid concentrating stresses. Dimpling the edge will add back any stiffness the plate loses due to the hole, probably make it stiffer than it was before you cut the hole. dimples / beads in a sheet metal part make it a lot stiffer than just flat sheet.
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