Header problem

[oglyoodoo]

Have at last got a bit of time to get everything ready for dropping the engine in. Decided to offer up and trial fit the shiny headers.
I can get four of the 6 fixing bolts in but the last two are not in line. Aggghhh...Why me??

The header flange looks as if it has been precision cut with a cut out out between one of the middle and end ports to miss a plug in the heads. If I put a straight edge along the bolt holes the end cylinder on both headers are a good 1.5-2.0mm out doubtless due to the flange not being bolted to something more substantial when welding. Additionally the header flange isn't flat where it joins the heads but maybe I can get that skimmed flat.
I dont think I can get the end ports bent back into line without causing damage elswhere it all seems pretty rigid. So the question is should I just try and file out all the header bolt holes to try and equalise the port misalignment or just tackle the one cylinder port that has the problem?? Any other ideas welcome. Annoyingly I have had the headers for about 5 years so it's a bit late to take them back. Just getting really piddled off with all the problems every time I get the odd precious hour to do something....

Denis

[wilf]

Par for the course I am afraid.

In your situation, I would try to open up every header bolt hole a little rather than one or two a lot...........after much sweat and persuasion they will eventually go on, and once they have been on there a while, will take up the new "shape" permanently.

Whne fitting mine, I try to get every bolt started by a thread or two to begin with, rather than run one or two right in. Gives more wriggle room.

[oglyoodoo]

Thanks for the helpful reply Wilf.
I just get a tad annoyed when you pay top dollar for something and it doesn't fit as it should. If they were prototypes or one offs I could accept it but once you have made a few it costs no more to get it right than it does to get it wrong.... It's so obvious why it is like it is and doesn't fit. I would be out of business If I made things that weren't properly compatible.
Down off soapbox and off to find some files. I think I'll also chamfer the header flange where it obscures the ports.
Thanks Denis.

[RichardG]

Originally Posted by oglyoodoo

Thanks for the helpful reply Wilf.
I just get a tad annoyed when you pay top dollar for something and it doesn't fit as it should. If they were prototypes or one offs I could accept it but once you have made a few it costs no more to get it right than it does to get it wrong.... It's so obvious why it is like it is and doesn't fit. I would be out of business If I made things that weren't properly compatible.
Down off soapbox and off to find some files. I think I'll also chamfer the header flange where it obscures the ports.
Thanks Denis.

Denis,

Is it worth talking to the supplier, explain your position and ask for a set that fit without fettling?

I guess without feedback suppliers will keep on flogging tat

Good luck, the old girl will be on the road soon enough.

[Kelvincob]

Hi Denis,

Glad to hear you are finding time to work on the beast, I know it's no help but I had the same problem, supposed to have been laser cut HaHa, I could have done better with a set of B&D diy tools, as Wilf said I opened mine out with a file, time will tell how they settle in. Sorry I can't be of more help.

Kelvin