Header installation - Need Help! - 986 Forum - The Community for Porsche Boxster & Cayman Owners

ohioboxster · 12-17-2006, 10:13 AM

Dont feel guilty, exhaust work is a pain and the bolts always break.

RandallNeighbour · 12-17-2006, 10:24 AM

The AC line was zipped tied to another line of some sort about 5 inches above the header area. This moved it away from the header by about 2 inches, enough to keep it rubbing up against it. Then, some heat-resistant silver tape was added to the line.

I watched the mechanic do this on my car.

I'm sure just heat wrapping the AC line would work, but moving it away from the source of the heat would give you a lot of peace of mind and keep the ambient heat of the AC line down. No sense in making your AC work harder than it should or risking an AC line from deteriorating over time due to the constant heat.

I'd get under it and photograph it for you, but it should be fairly easy to see what it can be tied to to keep it off the header.

As far as general heat from the new headers is concerned, I don't feel they are any hotter than the original headers and the interior of the car (using the right elbow thermostat against the carpet between the seats) does not seem to be any hotter than it was before... possibly a little cooler.

Che's muffler (or most any other smaller, two chamber aftermarket muffler, for that matter) sure is a lot cooler than the factory muffler though... you could bake a pizza in my trunk before and now it's warm, but not hot in there, even after a 4 hour drive in warm South Texas temperatures.

dcporsche99 · 12-17-2006, 10:30 AM

Hey Blinkwatt,
Here's one for you. This is the driver's side AC hose (top left) that's waiting to be wrapped. At least I opened up the garage to let some light in. I was doing some cleaning up so I decided to take this picture.

And btw, in the lower left hand corner of the picture...this is where the single bolt sits for the plastic cover that was hitting my head (re: see #8 on the list of silly things). I didn't put it back on yet. I'll do that after the shop fixes the broken bolts and studs.

dcporsche99 · 12-17-2006, 10:38 AM

Hi Randall,
Thanks for the info. I made the previous post before I had the chance to read your reply. Well, I guess it was meant to be that I take the picture to let others see what we're talking about. Thanks again!

I'm still some ways away from doing the cats and exhaust. But I certainly am looking to do it sometime in the near future. But, when that time comes I'll be sure to look back at all the useful info that you and the other guys were good enough to tell me about. Hopefully, I can make Ohio proud that I was able to proficiently use his torch heating technique on those darn bolts and studs.

dcporsche99 · 12-17-2006, 02:16 PM

Just a few more pictures from today with more lighting.

ohioboxster · 12-17-2006, 02:37 PM

They look nice, so is this at the exhaust shop or did you keep going?

dcporsche99 · 12-18-2006, 07:13 AM

Hey Ohio,
Thanks! No, these pictures were taken in my garage. I took the pictures while lying on my back (ouch!!). I was thinking about it, but I decided to wait for the next install (re: cats and exhaust) to take on your suggestion with the torch technique. Basically, I caved in :chicken: and made an appointment with my Porsche mechanic for tomorrow at 10am EST. When I called him, he told me that he had a 944 turbo just the other day with the same problem. Too bad I didn't know. I would have watched and learned.

dcporsche99 · 12-19-2006, 08:35 AM

Well, unfortunately my guy can't take care of it until the 26th!

So, I will have to be even more patient. It's all good. Some good FYIs came out of it though:

(1) Of course, Ohio was right! Apparently, those studs on the flange are heat-pressed. He's gonna have to take a torch to 'em.
(2) The new bolt that I managed to get back on the passenger's side flange (re: the one where the dremel did it's job) was a bit too long. Because of where it sits, after some time, I could easy end up puncturing the cover right above it.....and imagine oil all over the place...boy, would have been real bad!!!! Good to know!
(3) One of the bolts that I managed to break in the block is too far in, so he will have to drill it out and possibly retap it. And fiinally, the last bolt ( I just added the picture on the first post for this thread) can probably be taken out without having to drill it out.

So, I have learned a lot!

I will certainly make sure that any future installs will be inspected by him just to make sure I have covered all my bases. 'Til then folks! Have a good holiday and take it easy!! :dance: