Exhaust Header Fix for GT40P and others

fireguy50 · 08-27-2006, 12:06 AM

The last spark plug on the passanger side (#4) would not clear the header, others have had this issue with Headers.
Ford Racing 5.8L Truck Headers, part # M9430T58

I tried to add a dimple to clear the GT40P's lower plug angle, but it didn't work.
The dimple was doo deep for my aproval, and was still too close to the plug wire.

Here you can see the GT40P spark plug angle next to normal Small Block Ford plug angle

Step 1) We cut off the collector from the primaries.
Step 2) We cut out the #3 cylinder primary section we intended to replace

Here you can see the parts we cut out:

That stupid bung that was in my way:

Step 3) Cut and fit a replacement tube (Stainless 304 pre-bent 45 I got from http://stainlessworks.net ).
Step 4) Cut the original primary up further and weld the 2 pieces together.
Step 5) Weld the piece back to the exhaust flange.

You have to cut further up the primary so you can weld between them.
You could replace all of the primary if you didn't like the bends.

fireguy50 · 08-27-2006, 12:06 AM

Step 6) Weld all the primaries back together before they are hidden inside the collector.
Step 7) Next you have to cut and grind the to fit the collector.
Step 8) Time to weld the collector back on the primaries

You can also take this time to clean up the welds inside the primaries.

Starting dimple problem:

End Result:

We did remove the rear smog bung, it was late so we left the EGR bung, it's not in my way.
I'll get a picture of it on the truck Monday, with plug angle pictutres.

EZ SPEED · 08-27-2006, 03:02 AM

Great Job !!!

QWKSNKE · 08-27-2006, 07:51 AM

Nice work

SvoBrown · 08-27-2006, 08:42 AM

Keep it simple. Good work.

fireguy50 · 08-27-2006, 03:41 PM

Starting problem:

End result:

1sicklx · 08-27-2006, 10:16 PM

Nice fix.

Dale McPeters · 08-28-2006, 02:57 PM

Good Job Ryan....

ncontt · 08-28-2006, 07:19 PM

holy crap....that a way....show that header who's BOSS..

nice job

Italian LX · 08-28-2006, 08:10 PM

Nice work, Ryan.

08-27-2006, 12:06 AM	#1
fireguy50 Senior Member Join Date: Sep 2005 Location: MI Mental Health Dept Posts: 182	Exhaust Header Fix for GT40P and others The last spark plug on the passanger side (#4) would not clear the header, others have had this issue with Headers. Ford Racing 5.8L Truck Headers, part # M9430T58 I tried to add a dimple to clear the GT40P's lower plug angle, but it didn't work. The dimple was doo deep for my aproval, and was still too close to the plug wire. Here you can see the GT40P spark plug angle next to normal Small Block Ford plug angle Step 1) We cut off the collector from the primaries. Step 2) We cut out the #3 cylinder primary section we intended to replace Here you can see the parts we cut out: That stupid bung that was in my way: Step 3) Cut and fit a replacement tube (Stainless 304 pre-bent 45 I got from http://stainlessworks.net ). Step 4) Cut the original primary up further and weld the 2 pieces together. Step 5) Weld the piece back to the exhaust flange. You have to cut further up the primary so you can weld between them. You could replace all of the primary if you didn't like the bends.

08-27-2006, 12:06 AM	#2
fireguy50 Senior Member Join Date: Sep 2005 Location: MI Mental Health Dept Posts: 182	Step 6) Weld all the primaries back together before they are hidden inside the collector. Step 7) Next you have to cut and grind the to fit the collector. Step 8) Time to weld the collector back on the primaries You can also take this time to clean up the welds inside the primaries. Starting dimple problem: End Result: We did remove the rear smog bung, it was late so we left the EGR bung, it's not in my way. I'll get a picture of it on the truck Monday, with plug angle pictutres. __________________ Ryan J McCormick Parts replacement is not auto repair, if you can't diagnose, don't open the hood!

08-27-2006, 08:42 AM	#5
SvoBrown Senior Member Join Date: Nov 2005 Location: Graham AL Posts: 1,461	Keep it simple. Good work. __________________ ''Life's tough... it's even tougher if you're stupid.'' - - John Wayne

08-27-2006, 03:41 PM	#6
fireguy50 Senior Member Join Date: Sep 2005 Location: MI Mental Health Dept Posts: 182	Starting problem: End result: __________________ Ryan J McCormick Parts replacement is not auto repair, if you can't diagnose, don't open the hood!

08-27-2006, 10:16 PM	#7
1sicklx BamaMafia 4 Life Join Date: Feb 2005 Location: Lake View, AL Posts: 2,577	Nice fix. __________________ 1999 Ford F-150 Lariat

08-27-2006, 03:02 AM	#3
EZ SPEED Friends Join Date: Dec 2004 Location: Tempe Arizona Posts: 3,029	Great Job !!! __________________ 2020 Range Rover Sport HSE P525 Dynamic - Firenze Red - Supercharged 5.0 - 518 HP SOLD - 2010 Camaro SS [/B] - Featured in GM High Tech Performance and Camaro Now Magazines - http://www.superchevy.com/features/g...of-perfection/

08-27-2006, 07:51 AM	#4
QWKSNKE 3v's are slow Join Date: Dec 2004 Location: Here and There Posts: 17,152	Nice work __________________ 2009 Porsche Carrera S 2008 ///AMG C63.. Eurocharge Tune. RIP 2019 AMG GLC43..wife's 03 F250 SD.. Edge Evo, AFE Stage 1 CAI 08 GT. JBA axle back, FRPP springs, FRPP swaybars.. daughter's 01 Cobra vert... wife's I need a new toy

08-28-2006, 02:57 PM	#8
Dale McPeters 5.0 Block/Walnut Cracker Join Date: May 2005 Location: Working.... Posts: 2,409	Good Job Ryan.... __________________ '14 Dodge Challenger SRT8 392 6-speed

08-28-2006, 07:19 PM	#9
ncontt pro-jackstand racer Join Date: May 2005 Location: Milner, Ga Posts: 2,473	holy crap....that a way....show that header who's BOSS.. nice job __________________ And God created Neil Peart so that lightning would make sense to the world. ~~~~~~~~~~~~~~~~~~~~~~~~~~~

08-28-2006, 08:10 PM	#10
Italian LX Daddy x4 ...we're done Join Date: Dec 2004 Location: Oxford, AL Posts: 11,551	Nice work, Ryan. __________________ -Brian '86 Mustang GT Convertible '88 Mustang LX coupe '11 Odyssey TE '21 Insight Touring