Carpokes Porsche Forum

Tom wrote: Tue Oct 03, 2023 2:58 pm hmmm... if I'm doing metric right, .5cm is 5mm? 5mm is darn close by exhaust pipe flange standards. If I am understanding that correctly, then you just need to muscle it into position with a screwdriver or whatever it takes.

That's quite a find on the one-piece crossover!

ealoken wrote: Thu Oct 05, 2023 3:49 am Loosen them on the head, and sqrew all places inn,turn by turn.

Belgian951 wrote: Thu Oct 05, 2023 5:04 am

ealoken wrote: Thu Oct 05, 2023 3:49 am Loosen them on the head, and sqrew all places inn,turn by turn.

Exhaust headers are loose. Do you think it's safe to pry them this much together?

Belgian951 wrote: Thu Oct 05, 2023 1:32 am Thanks. I had my brother take some photos of the misalignment. What do you all think?
xover1.jpeg
xover2.jpeg

RUG8RB8 wrote: Fri Oct 06, 2023 4:06 pm You must have a set of quality tapered punches to make this happen. A generous amount of antiseize on your bolts and nuts will assist as well. You will have to play around with order of install as you will learn certain ones need to be started and other holes left open.

gpr8er wrote: Fri Oct 06, 2023 4:24 pm

Belgian951 wrote: Thu Oct 05, 2023 1:32 am Thanks. I had my brother take some photos of the misalignment. What do you all think?
xover1.jpeg
xover2.jpeg

The headers are most likely warped also a normal occurrence with these cars. That looks very doable. As others have said get a line up punch. Also FWIW I removed the studs in the head at the exhaust ports and used the same allen heads that are used for the intake manifold works really nice and when/if you need to R&R the headers you don't have to fight them to get around the studs. BTW when "we" say leave it loose that means only a few threads on the fastener.

Belgian951 wrote: Sat Oct 07, 2023 2:17 am

RUG8RB8 wrote: Fri Oct 06, 2023 4:06 pm You must have a set of quality tapered punches to make this happen. A generous amount of antiseize on your bolts and nuts will assist as well. You will have to play around with order of install as you will learn certain ones need to be started and other holes left open.

Thanks. I have bought 2 tapered punches, they'll arrive this evening.
Dumb question: do I have to hammer these punches at a sideways angle?

gpr8er wrote: Fri Oct 06, 2023 4:24 pm

Belgian951 wrote: Thu Oct 05, 2023 1:32 am Thanks. I had my brother take some photos of the misalignment. What do you all think?
xover1.jpeg
xover2.jpeg

The headers are most likely warped also a normal occurrence with these cars. That looks very doable. As others have said get a line up punch. Also FWIW I removed the studs in the head at the exhaust ports and used the same allen heads that are used for the intake manifold works really nice and when/if you need to R&R the headers you don't have to fight them to get around the studs. BTW when "we" say leave it loose that means only a few threads on the fastener.

I wouldn't be surprised if these headers are warped or otherwise damaged. I noticed the PO did a poor welding job on one of them, so I just hope they are leak free... But if I ever replace them, I'll be sure to change the studs to the bolts. That's a good tip. Thank you!