Advice/help with header install (watson)

[1991KOTH]

I hit a little bit of a roadblock with my Watson headers on the passenger side. I have removed the manifold, which has a triangular flange on the end of the manifold pipe. I had to hammer this off, but this flange wont fit on the longtube header. Keep in mind at some point in time the manifolds were switched to '95 manifolds; my car is a 91. Here is a pic. https://uploads.tapatalk-cdn.com/20170805/bd4a4886f887b04d5d70e6254e7a3913.jpg


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[Marc Haibeck]

The three bolt flange was used at the factory for '90 to '92 exhaust systems. In '93 the flange was eliminated and the connection to the exhaust manifold is a slip fit. The '91 flange was installed on your '95 manifold so that the '91 exhaust system would still fit.

With headers a roughly 10 inch long adapter pipe is needed on the right side. I believe that all of the Watson adapter pipes had a three bolt flange to connect to the exhaust system. A Jeal adapter with a three bolt flange will probably fit with a little modification. The currently available Stainless Works adapter pipe will fit except that it has a '93 - '95 style slip fit to the exhaust system. You will need to weld on a three bolt flange to fit it to the '91 exhaust system.

[1991KOTH]

The three bolt flange was used at the factory for '90 to '92 exhaust systems. In '93 the flange was eliminated and the connection to the exhaust manifold is a slip fit. The '91 flange was installed on your '95 manifold so that the '91 exhaust system would still fit.



With headers a roughly 10 inch long adapter pipe is needed on the right side. I believe that all of the Watson adapter pipes had a three bolt flange to connect to the exhaust system. A Jeal adapter with a three bolt flange will probably fit with a little modification. The currently available Stainless Works adapter pipe will fit except that it has a '93 - '95 style slip fit to the exhaust system. You will need to weld on a three bolt flange to fit it to the '91 exhaust system.


Thanks for the reply Marc! Im trying to fit a smaller tube into the header then sliding the flange onto that same tube to connect them but no one carries 2 3/4 pipe. Im wondering if I can cut that manifold pipe and use it as such.. the bend in it may complicate things though.


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[1991KOTH]

The three bolt flange was used at the factory for '90 to '92 exhaust systems. In '93 the flange was eliminated and the connection to the exhaust manifold is a slip fit. The '91 flange was installed on your '95 manifold so that the '91 exhaust system would still fit.



With headers a roughly 10 inch long adapter pipe is needed on the right side. I believe that all of the Watson adapter pipes had a three bolt flange to connect to the exhaust system. A Jeal adapter with a three bolt flange will probably fit with a little modification. The currently available Stainless Works adapter pipe will fit except that it has a '93 - '95 style slip fit to the exhaust system. You will need to weld on a three bolt flange to fit it to the '91 exhaust system.


Also; on the passenger side it looks like someone spliced the o2 sensor wire to the crankshaft sensor wire? It is very odd and im wodering if it can be a problem? The car runs fine as is.


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[Top Toy]

Auto Zone usually has 2 3/4" straight sections (around 18" long) of exhaust tubing on the shelf. Swaged on one end to slip over 2 3/4".

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[XfireZ51]

Also; on the passenger side it looks like someone spliced the o2 sensor wire to the crankshaft sensor wire? It is very odd and im wodering if it can be a problem? The car runs fine as is.


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WHAT...????.?!!!!

[LGAFF]

You might be able to use a flex pipe from a local auto parts store until you can get an exhaust piece made; the crank sensor and O2 come in through the same area from the front of the car, I don't think its spliced