Hi Guys, first timer here. I could use some help. I just installed my Thoreley's about a week ago, and am still dealing with headaches. The headers themselves are great, but fixing the two broken exhauset manifold studs has been a nightmare. After unsuccessful attempts to extract the broken stud, I tried to drill and tap it out and only made a mess of the head. So I took it in to the Nissan dealer since I figured they've fixed this problem a million times. After two days ,even the dealership gave up on fixing the holes I had made, and called in a "Laser guru" to work his black magic. Now the head and studs are perfect, but after 3 days at the dealer, I finally got it back today, and the driver's side header leaks worse than when I first installed it with the two missing studs (not ticking, but monster truck pull loud). The problem is that the damn EGR tube doesn't fit properly on the Thorley header. It about 1/4 inch too short and the angles on the fittings are a bit off, just enought that I can't start the tread no matter how loose the header is on the studs. I had the same problem when I tried to installed them the first time. After fighting with the EGR tube for a couple of hours, I finally had to take the header completely off again and managed to get it on by attaching the lower end of the tube to the header first, then the upper end to the EGR valve, and only they putting the header on the studs and bolting it down. unfortunately doing this twists the header (alot!) so it wont seat againt the head untill you start craking it down and puts a lot of stress on the newly (and painfully) installed studs. And of course, it doesn't seal properly on the header tube closest to the firewall is leaking like crazy. Rather than risk breaking another stud by overtightening the header to close the leak, I'm trying to figure out a way to modify/replace the EGR tube, maybe by cutting it and adding a flexible section ???, so the header can be bolted down properly.
Anybody else have a problem with attaching the EGR tube on the Thorley header? Maybe I just got a bad header from Thorley? (and yes, I did read and follow their detailed installation instructions) Any ideas on how I might modify the EGR tube (quickly, cheaply, easily) before I take the hacksaw to the sucker?
BTW my flanges are not flat either. I think this is by design and that it helps seal better around the exhaust port since due to the much smaller contact surface. The right side (no EGR) works great no leaks. Thorley does recommend a high temp sealant on the flnage side of the gasket. I used a copper/silicone and it works great.
Thanks Guys!
