ZR-1 Net Registry Forums - Header install tips and tricks??

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- - Header install tips and tricks?? (http://zr1.net/forum/showthread.php?t=8361)

Re: Header install tips and tricks??

When I did my headers, the stage 8 bolts, the clips would not fit into the bolts. Turned into a waste of money for the bolts.

Re: Header install tips and tricks??

Thank you, Dynomite! About how many bolts total can you get in there? I know that there are potentially 32, but from what I have read, that is impossible.
orthodoct

Re: Header install tips and tricks??

Quote:

Originally Posted by orthodoct (Post 215927)

There is controversy on the Registry regarding the length of Stage 8 bolts to use. I realize that the flange on my new SW headers will not be the same thickness as the stock manifolds, or will it? The Stage 8 kit for the ZR1 is 8mm x 1.25, 30 mm length. Dynomite mentioned using 8905 (20 ea, 8mm x 1.25 x 25 mm) and 8mm x 1.25 x 22mm which I can't find ANYWHERE (the 22mm ones). Having never done this before, are the bolt lengths different depending on where they go, or am I making a "mountain out of a molehill". Will the bolts supplied by SW suffice? I am planning on sending the headers to Jet Hot for ceramic coating. Seems as if SW doesn't do it. Sounds like it really knocks down underhood temperatures and cauterized adjacent structures (the surgeon in me coming out!) Thanks, guys. INCREDIBLE SITE! I have completely rebuilt the top end of my LT5 due to ruined injectors due to lousy E10 gas, PCV leak with lots of oil, replaced fuel pump assembly due to same, installed Elite Engineering catch can. Lots of solvent, q tips and paper towels. Bought a parts washer and was a very good investment. Any advice would be very appreciated. Jerry Downey and I have become great friends. He is an incredible resource and a patient, tolerant man who never seeems to tire of my questions. How do I become a member?

THANK YOU IN ADVANCE!
orthodoct

Couldn't agree more, Jerry is first class! :saluting:

Want to join the club?

http://www.zr1netregistry.com/Inform...HowtoJoin.aspx

Online or mail in a form

Welcome to the brotherhood!

:cheers:

David

Re: Header install tips and tricks??

Beautiful engine; I have spent several hours reviewing your posts/pictures.
Impressive!

Re: Header install tips and tricks??

Quote:

Originally Posted by orthodoct (Post 215931)

Thank you, Dynomite! About how many bolts total can you get in there? I know that there are potentially 32, but from what I have read, that is impossible.
orthodoct

It varies a bit but if you get say 12 each side you should be good (you actually could get by with 8 if they are staggered and you have at least one on each end). More is better. And.....try not to eliminate two adjacent bolts on the top or bottom row.

EXHAUST SYSTEM
Post 45 - Exhaust System Replace with Headers
Post 46 - Exhaust Headers Locking Bolt Tricks
Post 47 - Installing the LT5 with Headers TIPS

Re: Header install tips and tricks??

I have a 94 which has dowels instead of bolt holes on top left and right leaving 14 bolt holes per head. I was able to get bolts in all but one - 27 bolts. I used Stage 8 bolts and find it necessary to re-tighten these every so often due to bolts backing out. I had a discussion with Jim (QB93) today about cutting long end off of locking tabs that came with Stage 8 bolt kit and installing locking tabs as many as possible with the car on the lift. I think cutting long end off or grinding it down will allow it to slip on against the header runners and function as intended.
I will post up once we try this.

Re: Header install tips and tricks??

Dear David:
Trying to join as we speak!

Thank you!
TY

Re: Header install tips and tricks??

I reused the stock fasteners with the long spacer where they still fit, but I also ended up ordering a bag of these from Fastenal:
https://www.fastenal.com/web/products/details/0161882

https://img4.fastenal.com/productimages/19807_hr4c.jpg

13mm head with serrated flange head. Works well in a few positions where a box end wrench or 13mm swivels can grab them. In regards to the lock bolts, I didn't have that feature but retightened the hardware about 4 times before the gaskets shrunk and took a set. The have been tight every time I have checked since. I probably have 10 or 11 fasteners per side- much more than the stock 7. either way no problems.

Re: Header install tips and tricks??

Glad to be a member of the brotherhood!
TY

Re: Header install tips and tricks??

Amazon and Summit both offer the Stage 8 bolts, 32 in a package specifically for the ZR1, but they are 30mm long. Are they too long or will that work? Substantial price break as compared to ordering two packages of 25mm (such as 8906)??
Thanks everyone for their help. Will post some pictures once I am through with this project. I learned a few tricks that I think would be helpful to the group. I also am a ham radio operator and have restored a lot of tube ham gear (Collins) so wiring and soldering is not foreign to me.
TY

Re: Header install tips and tricks??

Quote:

Originally Posted by orthodoct (Post 215942)

30 mm is correct. Typically 2-3 have to be cut to 15-20 mm to clear the runner and start the thread.

Re: Header install tips and tricks??

Thanks, secondchance!
TY

Re: Header install tips and tricks??

Quote:

Originally Posted by secondchance (Post 215948)

30 mm is correct. Typically 2-3 have to be cut to 15-20 mm to clear the runner and start the thread.

The stock manifold bolts with spacer on 90' show 1 inch or 25mm of thread beyond spacer. The stock manifold bolts show about 5/8 or 16mm of thread beyond manifold flange when installed. Given stock manifold flange is relatively same thickness as header flange a 25mm stage8 bolt would engage head also about 5/8 in (16mm).

LT5 Summit Racing 8905
LT5 8mm x 1.25 The underhead length is 25 mm or about .98 inches

http://static.summitracing.com/globa...stg-8905_w.jpg

Re: Header install tips and tricks??

Quote:

Originally Posted by Dynomite (Post 215957)

http://static.summitracing.com/globa...stg-8905_w.jpg

Orthodoc,

To clarify - I think once I trim off long, triangular part of the tab, I can put the tab on and clip so the bolt won't turn.

Re: Header install tips and tricks??

I found out that Stainless Works does do ceramic coating, but it is not listed as an option on their website. Have to call them. Turnaround time for the headers, including coating is 4-5 weeks, so I guess that I know what I am getting for Christmas! Thank for the info, guys.
TY