Woot! Thanksgiving header install has started!
 

and I already broke 1 stud on the exhaust manifold so there's no looking back! If anyone is bored tomorrow before their big meal, you're welcome to stop by and laugh at me or with me. I figured it was worth it to try and tackle the job in a warm garage but I know I won't be done tomorrow so I have the weekend to finish hopefully.

what time are you heading out to get started?

ouch on the broken stud, did it break with enough sticking out to get vice grips on it or did it break inside the head?

Just 1? Slacker. Get a new impact gun and try again....

Ya break em all off its a lot easier :-P.

The stud was in the manifold that holds the cat-pipe on, not the head. I've been spraying them with PB blaster for 2 weeks and that one nut was seriously rusted and the electric impact gun snapped it. I was able to get all the other off and the drier's side manifold is now off. I doubt I'll get the passenger side off tonight, but we'll see. Probably starting tomorrow around 10-11. I'll be needing some extra sleep after today.

Heat it up RED hot and when you think its ready just touch with your finger to make sure LOL.

X2, ive had some asty looking bolts you never htought youd be able to turn without breaking them, but man when you PBthe hell outta it and then torch it, yeah 9 out of 10 times it turns and doesnt break

Well, tonight was a success other than the broken stud. Got the passenger side manifold out too. So maybe, the headers will go right in tomorrow with no problems. :roll: I know I'll need to do some cutting on the y-pipe to get the cats in but that's no big deal, I have a great hacksaw! :nod:

i wish i wasn't in NY, i would come help. i just did mine. just get the car super high up and it will slide right in. its not a super difficult process.

Maybe I'll help. But I prolly wot be awake til like 12. PM me though, il call and see whats up

I gotta grab breakfast first and then I'll be working til around 4. I appreciate the offers for help but don't worry about it if you're any distance away. I think I should be fine at this point. It definitely looks easier than that Pacesetter emission's header install I did on the old 96 SS with the minivan transmission. :(

Headers are in and bolted up. Y-pipe still needs to be put in and EGR/AIR stuff. Much easier than the LT1 headers. No hacksaw needed! :lol: It was very entertaining as I kept dropping header bolts and sockets. Perfect day with the garage open and warm air to work in. But now I'll need a new winter project once this is done. :doh: Oh yeah, these XS Stainless headers really are d@m nice and seem to fit well too!

Almost got it done in time to drive tomorrow. But the y-pipe is giving me some issues at the moment and I'm too tired and sore to finish tonight. Got pretty much every thing back on and in place and got it fired up running through the y-pipe that isn't clamped down all the way. It's not as loud as I thought it would be but I do have a cat on one side for now. I did have to go back and trim a corner off the engine block casting because it was closer than I thought.

Well, figured I would follow up with some issues I ran into. I did end up needing to trim back the corner of the casting flash on the block but that's not a real big deal. Then I noticed the car was shaking at idle and sounded like an exhaust leak or ignition problem. The scanner was showing activity on only 1 O2 sensor as well so that wasn't good. I kept getting a random multiple misfire code so I tried to drive the car and it shook real bad. I put it back on the ramps and figured I had cracked a spark plug or didn't have the wires on far enough. So I wait for it to cool and have a beer to think it out. :cheers: I knew it was on the passenger side and pulled each wire and plug to check them. First 3 were fine, I reach for the last wire and it's not even connected to the coil! Doh! Problem solved. As for the O2, I checked the extension harness and the 2 ground wires were crossed up so I cut them and spliced them back together. It runs a lot smoother on all 8 cylinders. :lol: I need more beer tonight so I'll take the test drive tomorrow. At least I had the chance to re-tighten the header bolts and put the Stage 8 clips and locks on while I had the plugs and wires out of the way.