Passenger header on hotair

[irockwithdirt]

Got my passenger header off yesterday...........they have been welded before. My reason for removing........my uppipe was rusted and cracked..........purchased new ATR up pipe. When installing, bolted to header and wastegate flange was 1/8" 1/4" away. Bolted down.......actualy pulled flange back and bent a bolt, which broke off when I tried to remove(my reason to remove). Had thought I might have crossthreaded but now I don't think so. Passenger header had been welded EXTENSIVELY in the valley where the uppipe lead attaches to the rest of the header. Thinking inlet may be pushed forward tworad front of car........warped, which may be the root of my problems. Does this happen on hotair cars? I've heard of people saying their headers are warped........is this what they are speaking of? Thanks for any help, Kevin

 

[BLACK Ttype]

I beleive they are usualy saying that their flange is warped.
This happens often if the manifold is welded without being bolted to something, like an extra head or thick piece of steel.

 

[HOTSIX]

I highly doubt the header has twisted or warped. It's rock solid and that's why it usually will crack in the first place as opposed to move a little.

I just bolted all my exhaust under the hood up two days ago.

I also have the ATR pieces.

You have to unbolt the turbo to engine mounting bolts, to loosen it and allow for a little movement during the bolt-up process.

Loosen turbo mounting bolts and have your header on tight, start the up-pipe to header connection a 'lil and do the turbo end of the up-pipe at the same time.

Gradually get everything tightened up a bit - dong a lil at each end - then finally tighten it all up.

It WILL come together. Doesn''t look like it will move that much when you are doing it - but it has worked every time I have done it.

I also use Ultra Copper by Permatex on each end of the up-pipe. That will help the seal but let it cure for at least 24 hrs before you start it up.