Sidepipe installation hints

[ERA Chas]

Here's a more involved but long term fix. And I know you've been through a lot lately...
Procure a junk FE head and clamp it to your workbench. Mount the head pipes and begin a process of fitting the collector pipes. Put a saw horse length-wise under the sidepipe for support.
The key a muffler expansion tool, commonly available at parts stores. Get one that has a 1-3" range.
Expand pipes as necessary to get a not-overly snug fit. Each pipe will be different. Sand areas where coating is too thick. Get them so that with the head pipes loose on their flanges the collector will slip on with a bit of effort-but no hammering stuff. And I didn't use any sealer between the pipes as it just shrinks away with heat. They won't leak if you work carefully.
Then, maintenance on the car becomes much easier.

[mrmustang]

I learned long ago the trick to installing 4 into 4 headers (although I had to be reminded of it this past spring)

1: loosen the header bolts so you can wiggle the header tubes.
2: Install (loosely) the rear bolt on the side pipe itself
3: Spray a light coat of PAM" cooking spray on the inside of the side pipe flange, and on the outside of the header tubes. You can spray it o a rag and wipe it on both pieces if you do not want to get over-spray on everything.
4: With the car either on a set of jack stands or wheel ramps in the front, slowly slip the side pipe to header tubes on while you are under the car. Each one is slightly longer than the other, so the first tube to hit is the first to get aligned, the second, third, and then final tube.
5: The header tubes should now be firmly within each associated side pipe tube. You can now wiggle the side pipe to get the bolt flanges to join each other.
6: Now bolt the flanges together (make sure to use a lock washer).
7: once flanges are firmly bolted together, retighten your header flanges to the heads.
8: Finally, install and tighten any rear mounting tab bolts, again remember to use lock washers.
9: Fire the car up and listen to how good the sound is.
10: Clean up and get yourself something to drink, you earned it.


Yes, it really is that easy.


Bill S.

[DanEC]

Originally Posted by ERA Chas

Procure a junk FE head and clamp it to your workbench. Mount the head pipes and begin a process of fitting the collector pipes.

In the event you don't have a spare junk yard head lying around or need one for a door stop - here is another approach. Get a piece of 1x6 poplar or other straight wood - lay your exhaust header gasket on it and mark the bolt holes - drill them out and bolt your header pipes to it. I welded some of my header tabs on using this method and they lined up perfect on the car. I bolted the left exhaust pipes on one side and the right exhaust pipes on the other side.

[ERA Chas]

Originally Posted by DanEC

In the event you don't have a spare junk yard head lying around or need one for a door stop - here is another approach. Get a piece of 1x6 poplar or other straight wood - lay your exhaust header gasket on it and mark the bolt holes - drill them out and bolt your header pipes to it.

Excellent idea. It should scare you that we think alike...
I'll repeat, no second helper, no lubricants/sealers, no hammers needed.
Beer is always a good idea.