Cascade Crew

Al Hasse · Posted: Thu Sep 06, 2007 7:05 pm Post subject: Headers are going on

After putting the sub frame connectors on, I gained an exhaust leak at the manifold to y-pipe junction on the passenger side. This was due to breaking the system apart to install the connectors, then it wouldn't seal (probably the first time it's ever been apart). I thought this was a good excuse to put my headers on, now that they've been ceramic coated. So I started collecting the parts I need to put at least the front half of the exhaust system together.

I bought a new 3" cat which fits over the y-pipe, a 3" to 2 1/2" reducer so I can temporarily use the present cat-back system. I have new plug wires with right angle boots, plug boot insulators and some exhaust clamps, header bolts, and gaskets. Saturday I'm renting a saws-all to cut the system apart at the cat and then install the new stuff.

Sellmanb · Member Joined: 30 Nov 2004 Posts: 727 Location: Tigard, OR

Awsome. What headers are you going with?

Al Hasse · Posted: Thu Sep 06, 2007 7:35 pm Post subject:

I have a set of Edelbrock short tubes and y-pipe with 3" outlet that I bought from alloy earlier this year.

Schultzy89GTA · Posted: Thu Sep 06, 2007 8:09 pm Post subject:

Al Hasse · Posted: Fri Sep 07, 2007 9:33 pm Post subject:

I got the driver's side bolted up, but not tight yet. Had to remove the valve cover to get clearance for the header to drop in. I was quite surprised at how clean it was under there, no sludge, just a little dark brown color from the oil. The previous owner was nice enough to install some pretty blue rubber gaskets, so I didn't have to buy new ones.

The passenger's side is giving me some trouble. That darned heat shield is in the way of everything. So far, after disconnecting most of the A.I.R. stuff, I still have 3 bolts to remove, and for now they wont budge. I shot them pretty good with some PB Blaster so tomorrow they might come loose.

Here is before I installed the gasket and bolted the header to the head and the valve cover still removed. Not bad for nearly 200K miles and for all I know, no rebuild...

Xophertony · Posted: Sat Sep 08, 2007 12:12 am Post subject:

are those ceramic coated black? nice.

aaron_sK · Posted: Sat Sep 08, 2007 1:41 pm Post subject:

91RSVert · Posted: Sat Sep 08, 2007 4:11 pm Post subject:

Same headers here sitting waiting for a y-pipe. Guess I should be taking notes Embarassed

Al Hasse · Posted: Sat Sep 08, 2007 5:44 pm Post subject:

Just happened to be the ones for sale that I picked up. I thought i was less hassle than deleting all the stuff anyway.

Now they're on. A broken spark plug while pulling the passenger manifold - I almost had it out and it slipped Mad

. For clearance, I had to remove the temp sender for the fan - what a mess, now I need to top off the coolant. I need to get a regular hex-head bolt for the hole behind #8 tube, due to header design, there isn't enough room for an allen.

As for the y-pipe, I had to persuade it to fit with the sub frame and sub frame connectors. I had to put a dent in them where they would meet the sub frame behind the wheel and another dent where the sub frame connector crosses from the transmission tunnel.

Now to the small stuff left to do. I need to replace 4 spark plugs (driver side), lengthen the wire to my O2 sensor (it's farther downstream now, connect the catalytic converter mounting brackets to the transmission mount, and connect the air tube to the catalytic converter. After all that, I should take it to a muffler shop and have it checked for leaks.

This is where the y-pipe rests against the sub frame and sub frame connector.

The driver side finished up. Passenger side is hard to see due to the A/C and emissions stuff.

83Z28BlackBetty · Posted: Sat Sep 08, 2007 6:47 pm Post subject:

looks super good Al, I need ot get on that myself! Razz

~JAKE

alloy · Posted: Sat Sep 08, 2007 7:04 pm Post subject:

I'm glad the headers are working out for you Al.

Twilightoptics · Posted: Sat Sep 08, 2007 11:42 pm Post subject:

Be careful on those air tubes. they CAN burn your plug wires.

Al Hasse · Posted: Sun Sep 09, 2007 6:59 am Post subject:

Thanks Paul, I'll have to do some re-routing. I forgot they get almost or as hot as the headers,

Xophertony · Posted: Sun Sep 09, 2007 10:03 am Post subject:

summit sells fire boots that cover the first 8 inches of your plug wires. i highly recomend them. the plug wires on the six have gon almost 3 years now without getting all cracked. and i have yet to burn one on the GTA (where the boots protect anyway).

Al Hasse · Posted: Sun Sep 09, 2007 1:40 pm Post subject:

I tried to put on some fire boots from West Bay, but couldn't get them to slide over the angle boots, I'll have to look into those at Summit. I have one small leak on the passenger side, I was unable to put in the bolt behind #8 tube because of a clearance issue ( I can't get a wrench on it).

It's almost all together now and running. At idle I get a small backfire through the exhaust, but running through the higher RPM band (still in neutral), it runs really smooth. Is this just a timing issue now, or something the ECM doesn't like?

rjmcgee · The Hammer Joined: 08 Jan 2004 Posts: 2328

Looks good Al. That should wake her up a little. Smile

Al Hasse · Posted: Mon Sep 10, 2007 10:14 pm Post subject:

I might have to get a different y-pipe made. This one rests against the sub frame and vibrates really loud under acceleration. Maybe I'll have one made when I finally get the cat-back system made up. Razz

Twilightoptics · Posted: Tue Sep 11, 2007 7:04 am Post subject:

91RSVert · Posted: Tue Sep 11, 2007 11:36 am Post subject:

Hum, no subframes on mine yet, and mine didnt come with a y-pipe either.

So you have to remove the fan sensor to get it in-n-out. Or do you think with ac-delete it will be easier to deal with?

Al Hasse · Posted: Tue Sep 11, 2007 12:26 pm Post subject:

I have A/C on mine, so the A/C delete would make it easier. I also removed the starter to install the passenger side from the bottom. As for my y-pipe, when I get a new one made or modify this one, I'll have it flanged at the cat (and have the cat flanged) so I can drop the y-pipe to access the starter for service.