Header installation problem

[240ZMan]

So I put my new MSA header on yesterday and got the piping and all that sorted out. However, the flange on the header isn't as thick as the intake manifold. I had hoped that this wasn't going to be an issue so I just used the thick washers from my original exhaust manifold and let them settle at an angle on the studs that hold both the intake and exhaust. But I can hear at least one exhaust leak so I guessed wrong.

What have others done? I fabricated a heat shield so I'm probably going to have to remove the carbs completely as well as the shield in order to get at the manifold bolts. Not a hard job, just not very satisfying when done for the 2nd, 3rd, time etc. So I'd like to just do it one more time and be done.

Thanks,

[PrOxLaMuS©]

Hey! A colorado Z car owner!!!

WHoo hoo!!

Sorry, I can't help ya with your problem... but I too have a set of headers I will eventually put on.. someday... so this might help me out

You live in Castle Rock? I'm in Centennial.. Let's meet up sometime! :classic:

[panchovisa]

Have a friend with a lathe make some spacers (or visit a machine shop) to sit on header flange to bring thickness up to intake thickness.

3/4" o.d by 3/8" i.d by approximately 1/4" thick (you must measure the offset between flanges) should do it. You will have to saw corners off spacers to fit on stud and next to intake. Will probably cost $2 each.

You don't have to remove intake or header to fix this way. Otherwise you will need the flage of intake milled thinner where intake and header share a stud. Will probably cost $100.

[kinfish]

Common problem in that MSA header flange is thinner than the stock intake manifold. Using stock washers tilted between adjacent flanges will not provide any clamping load for sealing and may damage the studs in the head. Best solution is to make special washer with step to accomodate the difference in flange thickness. A machined version would be optimum but a quick fix can be achieved by finding washer same thickness as step, grind off side leaving about 225 deg arc and tack weld it to the stock thick washer. Orient the step on the washer to contact the header flange. Torque to spec and should seal perfectly.

MSA could improve Customer satisfaction if they supplied these special washers when they sell the header .... but they don't. Even better would be to change the header design to elimiate the step. ...... Duh, that would be too simple.

[zztom]

Or you could send the header back and get a 6-1 header from Arizona Z-Car. It bolted right up with no problem.

[zztom]

Looks good too!!:classic: :classic: