Header installation - Need Help!

[dcporsche99]

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]

Just a few more pictures from today with more lighting.

[ohioboxster]

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

[dcporsche99]

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]

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:

[dcporsche99]

Hey Folks,
Sorry, it's been awhile. After all that time, it was ONLY TODAY (re: 5-10 Degrees in New York) that I finally completed the job with my porsche mechanic. The holidays were hectic and I didn't get a chance to finish everything on my last visit with him so the car basically sat this whole time. But, TODAY I FINALLY have my car WITHOUT THE EXHAUST LEAK!! WHEW!!!....and I have to say that it sure sounds and feels great! :dance:

Other NEW issues:
(1) I do have to take care of a CEL that came on prior to my last visit to him. It was pretty damp and foggy that day. It came on when I went through a puddle of water. Ever since then, it's been on. So, I'll have to take care of that issue before I take my ride out for a REAL TEST DRIVE. Looks like I will be purchasing an OBD II reader as well.

AND

(2) I have some vibration that I have to take care of. It sounds like it's coming from the ???firewall /heat shields/ baffles??? from on the driver's side. I have yet to search our site for some solutions other than removing them.

Would certainly appreciate any input from you guys! (Nevermind, thanks anyway...found all the info from previous posts!)

[dcporsche99]

Well, the CEL issue is fine now. My brother cleared the codes for me and we took it for a test drive the other night. So far so good! Thanks bro!

Now for that vibration....after using hose clamps on just about anything that was close to where the vibration was, I did find out where the biggest vibration was coming from. Wouldn't you know it, the passenger side header. ***So Blink, if you are reading this, I would highly suggest purchasing headers from someone else. At least, a company that provides a warranty of sorts***There are two areas that come very close together. Starting from the 1st pipe closest to the front of the car...so far, I have just finished wrapping a portion of the first pipe and it seems decent enough. (re: I guess this is where my tennis racket wrapping experience came in handy). Now I need to get to the local hardware shop to buy a few more hose clamps (even though I suspect I will need just one more, but just in case).

***On a side note: Just wanted to say thanks to Randall for the post on how to fix the front and rear truck lid. The other day they both stopped working, but THANKS TO THIS FORUM and Randall's post, it's back in working order.**** :dance: