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Scott,
I've had the same problem with my slip fit header to side pipe connection and I'm about 99% certain that is the cause of your backfire. I've tried just about every type of "goop" there is out there and none of it has lasted for more than a couple of months. I've used the hi temp silicone that some have recommended and it lasted no more than a couple of hours. The best stuff I found was some black tar like muffler sealer that I bought at a Napa auto supply store but it would only last a few months. I finally made some modifications to my side pipes to solve the problem. I just got the car back on the road yesterday after making the mods and so far so good. I'm confident I've solved the problem.
When I get home tonight, I'll take some photos and post them here so you can see what I did but I'll attempt to describe it too. I removed the side pipes and welded a 1 inch long piece of 1/2 stainless tube at the very end of each sidepipe opening (I welded it perpendicular to the sidepipe opening). I then used a die grinder with a 1/8 think blade to cut a notch through the stainless steel tube and the sidepipe (make sure you cut the notch to a depth that is less than the distance that the header slides into the sidepipe). I then inserted a 1/4 in bolt through the stainless tube. After reinstalling the sidepipes, I can then tighten the bolt which solidly clamps the sidepipe to the header.
Chris
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