I pulled my exhaust manifolds today to correct a darn big exhaust leak on the drivers-side rear. I wasn't intending to pull the manifolds, but I checked the bolts to see if I could move them at all and surprise, surprise, they all moved with (relatively) little effort. Pulling the manifolds was a real PITA as a result of bolt location but the passenger side went much easier than the drivers side.

Once I got the manifolds off, I got to thinking whether or not I ever wanted to do that again. Because headers are one of the many planned upgrades to this 390 and the manifolds are off now, should I go ahead an upgrade? If that's the case, can I install them myself or would I be better off taking the rig to a muffler shop sans exhaust manifolds (a deafening experience to be sure) and have them install the headers? I'm really not certain if I'm up to the task of cutting the headers to make it around the starter and modifying the rest of my exhaust the fit the headers.

Could anyone give me a ball park cost estimate for having headers installed at a muffler shop?

Anyway, I was surprised at how smoothly the removal went. No broken bolts, no cross threaded bolts, no real issues other than I just couldn't get my fat hands into a few spots.

The drivers side manifold had a serious leak:




Two different sizes of bolt on the drivers side manifold. It was the top front-most bolt that was 1/2" rather than 9/16" like all the rest:


Thanks for the thoughts,

Fish

 

If you plan on installing headers now is the time to do it.
As for having to mod them to get them to fit around the starter, any quality set should fit without having to cut them up.
There could be some issues wth the bolts. The one you pulled out was a 5/16" bolt (1/2" wrench size). Probably in the past someone has either stripped the threads in that hole or the bolt wrung off and they just drilled a hole through.
If you do go the header route and haven't bought them yet, avoid going cheap. Stay away from headers with 1/4" or 5/16" thick flanges. These are guaranteed to leak. Go for at least 3/8" thick flanges and 16 ga tubing. In the long run you'll be doing yourself a favor.

 

Nooo, do not drive without manifolds. I would just do them at home. Prep and take your time. Done right you wont have any leaks. Unless you have POS flowtechs off the clearance table at checker like i do on my bump lol. But if you dont wanna bother with the clearance issue id re install the manifolds and take it to a shop.

 

This.

You can cause damage by driving without the manifolds installed.

 

If you go with headers I would get fender well exit instead of chassis exit. I had to do modifications to my transmission cross member in order for them to work. I also have to notch the frame out on the passenger side and re-route my transmission lines and battery cables.