I love my headers, no, I hate my headers.....

Finely got around to installing the aluminum header gaskets. Or should I say trying to install my header gaskets. Started on the drivers side, it was leaking the worst. Got all the bolts back in except one. Damn thing will not start back in. It gets to the point of feeling like it wants to start, and then kicks out. I've tried three different bolts, loosening all the others, tightening all the others, even trying to start that one first to no avail. Stupid design of the Hookers, you can't get the bolt to go in straight, and when it is straight, it's too short, you can't get the flange close enough to start it without the other bolts being in first. Can't get anything in there to bend the tube either, tried that.
Steering box is too close to get the header pried out to see whats going on. I'm pi$$ed. It came off fine and went back on fine last time.
I wish I had of noticed how close the clearance is on the back side of the tubes when I put them on the first time. I could have taken a BFH and dented them at bolt holes. Pi$$ poor design from the factory. The tubes should have been dimpled so you could get a socket on the bolts instead of having to use an open end wrench!

Sorry for the rant, but sometimes little things like this get my dander up. I may have to jack the damn engine up just to start that one bolt.

 

Headers have always been a source of aggravation, constantly having to tightening the bolts once you finally get them in and started, I have a couple shorter bolts that I put in the harder to start holes and never ever tighten a bolt until they are all started, and pulling the started is a lot of fun as well. arghhh I feel your frustration sometimes its best just to walk away for a few minutes

 

I think this why my set of headers are still hanging on the wall I never got brave enough to try and put them on.

 

I like the allen head bolts myself.

 

i remember test fitting mine on my motor before i put them on. i ended up grinding one of the holes for the header bolts to get it to line up. you may want to try drilling the trouble hole one drill bit size bigger to give it some more room.

 

I've also tapered the end of a bolt on a bench grinder for those hard to start bolts...Kind of self centers it as you start threading it

 

I had those, they were harder to put in than the regular header bolts. The way the tubes turn back so sharp, you couldn't even use them on the rear holes , the heads were too big. And the allen socket was too long, especially at the shock towers. I had to use a 8mm wrench on the allen to tighten them up. A pain, so I went back with the regular header bolts.

Yeah, I tried that one, too. May not have tapered it enough, because it wouldn't start, either. May go back and grind it some more and see what happens.

Probably won't get a chance to try again until next weekend. Was hoping to get-r-done before Dec 3rd so I could take her to a benefit show for a children's home. Time has been full of other stuff lately, and looks like it will be for a while.

 

Use the ARP bolts, first off, they are easier to get a wrench on. Part number 100-1202. Not really expensive, but use a smaller sized wrench.

And of course, dimple the tubes just near the holes. Keep hitting with a small body hammer until you can push the bolt straight into the hole without hitting the tube.

I have thought several times about going back to plain manifolds.

The headers have been more hassle than they are worth.

Let's see, after the headers, I needed to change the following...

1) entire new exhaust system
2) I lost my side pipes
3) lost my column shifter
4) lost my kickdown rod (don't remember if because of headers or not)
5) drop-down bracket for power steering.
6) shock tower shaved
7) and much louder, and a source drone noise.
8) hotter under the hood, so lifted the rear of my hood for a "cowl" effect

and with GT40P heads, even more hassle with spacers, extra gaskets, varying length bolts, etc. Burned plug wires, $16 each shorty plugs....

I was much happier with stock manifolds...

 

Shave the towers off.. problem solved

 

The bolts that I am using now have a hex head on the outside and have allen head on the inside of hex head, helps with getting them mostly tight but still have to use the wrench to get them really tight.

 

Gene, I've been thinking about doing that very thing. Planning on a new engine in the near future, kinda waiting until I get that built so I could do it while the engine was out. Also thinking about losing the black engine bay and going body color. Lots of thinking going on, very little progress!

 

Thinking is the cheap part When the thinking turns into doing ,watch out wallet, this is going to sting a little

 

after this discussion I think I'll put the headers back in the box for now...

 

ARPs

 

Must have been the laminated gasket holding it off. Walked over to it today, that one bolt started right in. Put the passenger side on in about 20 minutes! Still got a little leak on the passengers side, gonna retighten it tomorrow. That is, if I can get to it before I eat. No way I'll be able to bend over after that big meal tomorrow!