I know the subject has been worked over here many times; this approach is a little different. Because I am performing a restification to my truck I’m being a little more **** about the fit and finish of the end product. I’m old, I’ve earned it. I’ve installed 3 sets of headers in the last month. Third time is a charm. The truck: ’77 F150 4x4 w/400 and automatic, no modifications to the suspension. The first set of headers I installed was the Dynomax Jet coated units. Very nice looking and I was impressed with the coating, almost like they were chrome. After I got them installed I found I couldn’t hook up my front driveshaft. Bummer. Next was a set of Headman Elites. I was impressed with the complete package they sent. They are also heavier gauge steel then the Dynomax. Although difficult to install as per instructions (remove the starter, disconnect rt. motor mount, jack up engine as high as possible, remove rt. mount tower) they did fit and clear everything; starter, driveshaft, etc., after I got it all back together. Clearance at the outlets was an issue though. The collectors ended very close to transmission cross member and were pointed right at it. Not above it or below it but right at it. The first thing the muffler shop wanted to do was either modify the new headers or start cutting and modifying my cross member. NOT! Next I installed a set of Sanderson headers. Notice that they keep getting more expensive. These are shorty headers originally made for the 351 Cleveland w/4V heads so the primary pipe is 1 7/8”. I really didn’t want to go that big but I was running out of choices. I don’t think I will ever notice the slight loss of low end torque because of bigger primary pipes. These were by far the easiest to install on my truck. Both sides went in from the top of the engine. I have factory air so the right side doesn’t have a lot of room. I also left the bubble wrap on the pipes to protect them from getting scratched up during installation. They went in real easy. Sanderson gave me the copper manifold gaskets, the copper collector gaskets and the angled collectors as part of the package. I asked for them then complained about the cost. I chose to go with a 2 into 1 system on my truck, 2 ½” from the collectors into a 3” single and 3” all the way out the back. The muffler is a series 70 Flowmaster. I got the throaty sound that Flowmaster is noted for but no loud noise. I think it is as quiet or quieter then the stock system. 2 into 1 is also half as much tubing, half a many mufflers, half as many clamps to leak, half as much to get tore up off roading. Take a look at my gallery to see the installation. I’ll be glad to answer any questions either by posting or e-mail

 

There is also a thread on this in 73-9 for replies and questions so we can keep all of the info in one place:

https://www.ford-trucks.com/forums/s...d.php?t=378226