Yippee!!! Finally broke a manifold stud (or two) - Page 6

Krewat · #76 (**permalink**) 04-09-2007, 11:17 PM

Good point, but couldn't find any studs. Didn't want to use Ford's again, no matter what they say.

I'll get those dirty *******s in, so help me

1 · #77 (**permalink**) 04-10-2007, 01:33 AM

How about some nice ARP bolts/studs? Never have to worry about problems with those.

Krewat · #78 (**permalink**) 04-10-2007, 10:48 AM

I got plated grade 8 bolts that will work perfectly, and I'm using anti-sieze on them.

Problem is clearance. On certain bolts, I had to keep the header loose and then start them into the threads just to get the bolts in.

I'm using MUCH longer ones than what came with the headers. The supplied bolts got less than 1/2" into the threads. Way too little for aluminum ...

I'll be jacking up the driver's side of the engine today to get to the bottom bolts, I'm certain

Krewat · #79 (**permalink**) 04-10-2007, 10:50 PM

Some pics, hopefully they wind up in the right thread this time

Krewat · #80 (**permalink**) 04-10-2007, 10:53 PM

The engine is jacked up on the passenger's side, so they won't look like this with the engine sitting properly...

Whew! Some of them bolts were a pain in the butt. I am going to re-visit one on the passenger side, I couldn't get the long ones into that center bottom hole... too long. Had to use one of the shorty ones from the kit - and there's no way I'm leaving it with only 6 or so threads grabbing. I have to go find an inbetween one now...

Driver's side, still have to get two bolts in, # 7 and #8 bottom holes are another pain. Probably going to need shorter bolts there too...

It's fun using both index fingers to reach around the tube and try to thread in a bolt - when the flats of the bolt head are flush with the tubing - even when you try to lever the thing outward to get the room to get it in...

My shoulders are PUMPED.

dkf · #81 (**permalink**) 04-11-2007, 08:48 AM

Those E-Bay headers look pretty good. Look a lot like JBA headers.

You could just cut down a long bolt with a cut-off wheel on a dremel tool and file the threads so they start. Sometimes you just can't find the right length bolt.

Super08 · #82 (**permalink**) 04-11-2007, 09:21 AM

Art do those puppies look real good. I agree on the Dremel tool idea. I've had mine since '82 and always find a use for it. I had to cut some bolts with mine two days ago putting a fifth wheel hitch in my new truck. What a job that turned out to be....another story for another day.

sewerat · #83 (**permalink**) 04-11-2007, 12:49 PM

so are you going to have to modify the exshust pipe to make it fit up to the new headers or is this a plug and play...so to speak. that is one reason i did not go with them when i did my manifolds in december is that i could not afford the time or cost of redoing the main pipe to fit onto the new collector so i opted not to for the time being.

Krewat · #84 (**permalink**) 04-11-2007, 03:20 PM

So far, it looks to be a bolt-in. As long as you consider notching the frame "bolt-in".

Otherwise, yeah, it really REALLY looks like it'll just mate up to the stock y-pipe.

--

On another note, found better (longer) bolts for that one center bottom (#3) bolt on the passenger side. Still not as long as the rest, but definitely long enough for aluminum and the torque required.

Passenger side is IN. Notching the frame a little more (really increasing a radius), but other than that, passenger side is done.

WHEW.

Now on to the driver's side - after using the grinder that almost took my finger off two years ago

Krewat · #85 (**permalink**) 04-12-2007, 10:27 PM

Didn't get out in the pouring rain today to do anything. Where I have the truck, it floods with about 3-4 inches of water when we get an inch or more of rain...

I'm just glad the jackstands on lumber are staying where they are... the mud back there is horrendous.

Anyway, will go out tomorrow and continue trying on the driver's side.

Still fighting three bottom center bolts... I can hardly get two index fingers around the tube to try to turn the bolt... and a wrench? Impossible when the bolt head is too close to the tubing. I might have to remove the steering shaft to get in there.

I did have to disconnect the steering shaft at the box to get the driver's side in. Make a note

mont974x4 · #86 (**permalink**) 04-12-2007, 10:58 PM

Those headers do look darn good.

*sigh* another thing to add to the wish list.

FORDTUF1 · #87 (**permalink**) 04-13-2007, 12:09 AM

KREWAT, Dude your making me feel like a Super Stud.

I put my JBA's on my 99 and it took me 10 hours, and I felt like crap it took so long. The only thing I had to do was cut down a 13mm combo wrench. Man I hated that, I now own a set of stubby wrenches.

I got my 02 and it took me 4 hours to swap the stock manifolds back to the 99.

By now I was getting the hang of it, it took 8 hours to get them on the 02. Wouldn't you know the gaskets then leaked after three years. But now I'm an expert 2 hours off and 4 hours back on, 6 hours total.

Guess what now, they are about 7 years old and they have a leak where the 5 tubes are welded at the collector. Here I go again, I think it's just a test to see if I can break the 5 hour mark.

Krewat · #88 (**permalink**) 04-13-2007, 09:46 AM

FORDTUF1, believe me, I don't fell very good about myself taking THIS LONG.

But, broken studs, below the surface of the head, finding the correct length bolts, a few "gotchas" with these headers that might not happen with "brand name" ones, etc. etc.

It's taking a long time in elapsed time, but total labor, maybe 16-20 hours so far.

Trying to finesse things when I should have just gotten the cutting torch certainly cut into the time needed too...

Trying to work around things instead of just removing them, another bit of time.

Going to the auto parts and hardware stores around here at least TEN TIMES for various things, bolts, tap, you name it.

I also spent time painting the chassis on the passenger side, just to make it look nice for the final pictures.

Taking my time doing the job always rewards me in the end. So...

Super08 · #89 (**permalink**) 04-13-2007, 11:07 PM

Art are you able to post sound clips? If so, I for one would love to hear how it sounds once you are done.

Krewat · #90 (**permalink**) 04-14-2007, 10:31 AM

Oh, I'm able, and will definitely do it.

I had to remove the driver's side manifold, something doesn't line up, hence the problems getting the last two bolts in. I'll delve into it an hour or so today, and see what I come up with. It might be the one bolt at the rear top, the hole is slotted, and I'm using a flat washer on it, which might be in the way ...

Anyway...

We have a nor'easter coming, supposedly one to rival any floods we've had in 30 years.

Yay... truck is in what will become the muddiest part of the yard... Maybe (probably) I'll build a lean-to today and see if I can dent/scratch the truck (some more).