Topic: Header install tips/tricks (4:1) ??

[BlackMax]

I figured it would be as easy as it was taking them off......woops.  Uh, also which way are the collars oriented?  Double ridge towards the front or towards the head??    Yea, I know....   But i rarely do stuff myself, so it's the little things that bog me down and force me to ask dumb questions.  

[Alan F.]

2x4 blocks, or even a stack of newspapers or magazines under the header will help keep it from dropping to the floor while your hands are full of flanges and nuts/bolts... a helper is also beneficial. Alcohol is very useful, just remember not to tighten anything down until you're sober.

[BlackMax]

Did it.....uh, that really wasn't much fun though

I also found that the gaskets I gave my engine builder were not used.  Does everyone use header gaskets?   For now, I'm forgoing them. 

[Industrial Cafe]

little copper round ones? 
if so, you're gonna want to put those on.
unless you just left the old ones in

[BlackMax]

little copper round ones? 
if so, you're gonna want to put those on.
unless you just left the old ones in

Yea, the copper ones.    The thing is, I am pretty damn sure there were no gaskets in there when I got the bike back, and it didn't leak.  Now, I just put the headers back on.....made sure the pipes were in the correct seat, and bolted them up......but every single one is leaking like crazy???!!!!    Now, how on earth could I screw this up??

1) pipes seated against the head
2) collars (2 pieces) around the pipes, seated with the longer side down inside the flange
3) flanges bolted to the heades, nice and snug.

.....still, it leaks.  One pipe is noticably loose, even though the flange is as tight as it will go?  I guess this is where the gasket comes into play?  But, how did the previous guy get them to seal without gaskets?   Any idea what i may be missing here?  It seems so easy, but......

[Industrial Cafe]

when i did mine, it looked like there were no gaskets in there.
 but i wiped around with a rag and saw them, pulled the old flat ones out put the new ones in and VIOLA

[Gordon]

Yea, the copper ones.    The thing is, I am pretty damn sure there were no gaskets in there when I got the bike back, and it didn't leak. 

That's pretty much exactly what most people say who haven't ever had to (or bothered to) dig out the old exhaust gaskets before.  They're in there, they just blend in with the port because they're the exact same shape/size and covered with soot. 

[BlackMax]

They were in there...and fine to re-use.   

My problem was that i had the collars on upside down, thus not allowing the pipes to tighten adequately against the gasket.  Flipped them around, and presto.

[gane]

Too late, but tips none the less. old exhaust gaskets usually like to adhere to head. and in most cases are fine.tho replacement is optimum. if replacing, the copper/asbestoes doughnuts are best. a light skim of wheel bearing grease  at head side will keep 'em in place while jiggling headers in place. a quick wrap of masking tape around 1/2 moons keeps them roughly in place. (angled end out). Headers often relax upon removal and must be tweeked/ perswaded back into exhaust ports. once every one is roughly in place, and loosely secured, give a couple shakes. look around for escaped gaskets, then gradually tighten collets from inside out. It's not uncommon for 4/1 headers to vary as much as a inch relaxed at head insert, nothing to be concerned about. just insure every one gets home. a dab of anti-sieze never hurt, and if have had problems w/ nuts backing off in past, simply "pal-nut". Exhaust studs are an area where "less is frequently more",  A broken exhaust stud  is usually expensive, and always awquard. luck g

[Industrial Cafe]

I just buy headers to fit an earlier bike 69-76 i think, and pull the studs.  never liked the collars.