LT1-LT4 Modifications 1993-97 Gen II Small Block V8

First header install

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Old 09-22-2007, 09:16 AM
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Default First header install

How long should it take me? I have all the stuff, and power tools, Im lazy I know.
Old 09-22-2007, 04:01 PM
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An hour into and got 1 manifold off (drivers side, I went the easy route first LOL!) So nothing toooooo hard except one of the back manifold bolts.
Old 09-22-2007, 04:17 PM
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I've only done long tubes but most people take around 8 - 10 hours first time. Make sure you anti seize the header bolts before putting them in.
Old 09-22-2007, 05:55 PM
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Originally Posted by Slowmaro95Z28
I've only done long tubes but most people take around 8 - 10 hours first time. Make sure you anti seize the header bolts before putting them in.
Oh for sure, and the plugs...What gap does most you all go on some Tr55's? mods in sig.
Old 09-22-2007, 10:08 PM
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I have more mods than you and I am running .050 gap with those plugs. Seems fine to me.

Power tools to remove the bolts that connect the manifold to the y pipe are a life saver. Also a electric saw is nice to cut the y pipe off.

The pass side LT header is a PITA if it has the egr and air tube. Without them they are pretty easy really. Slid right in.
Old 09-22-2007, 11:20 PM
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I gapped mine at .044 is that going to be ok?
Old 09-23-2007, 01:40 AM
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5 hours....Got the drivers side done, plugs and all, and 3 bolts from the pass. side manifold. Im done for the night. There are some header bolts on the pass. side that just ******* suck ***.Any pointers to get the first and last bolts out? Ive been hosing them in PB break free.
Old 09-23-2007, 02:30 AM
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Can't remember what I did but I remember those bolts being a PITA. 5 hours honestly isn't bad for your first time. People usually don't think ahead about stuck bolts and other things that hold you up for a few hours. Good luck and I want to hear a sound clip when this is done.
Old 09-23-2007, 03:11 AM
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Originally Posted by Slowmaro95Z28
Can't remember what I did but I remember those bolts being a PITA. 5 hours honestly isn't bad for your first time. People usually don't think ahead about stuck bolts and other things that hold you up for a few hours. Good luck and I want to hear a sound clip when this is done.
Yeah I did things a little backwards, but Im on track now. See how them bolts do tomorrow. Ill try and get a sound clip as soon as I can.
Old 09-23-2007, 03:21 AM
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Hell, putting my header bolts in my 95 with the BBK shortys sucked, the 4th and 5th ones back on the driver side just pissed me off. Prolly just because im impatient and barely moving a bolt in one bit at a time is kina agrovating.
Old 09-23-2007, 02:04 PM
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Originally Posted by ZONES89RS
Hell, putting my header bolts in my 95 with the BBK shortys sucked, the 4th and 5th ones back on the driver side just pissed me off. Prolly just because im impatient and barely moving a bolt in one bit at a time is kina agrovating.
I agree, I had a friend come help for the last little bit, we are going to get started on in today here soon. Time to get annoyed with some bolts!
Old 09-24-2007, 08:48 PM
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Well after taking a break, Ive gotten back to it but have a few Q's. The mount for the ALT that bolts to where the stock exhaust manifold was, does it have to be there? It doesnt look like a bolt will fit over my header flange. The extra holes where the exhaust manifolds had an extra 2 holes on each side, do those have to be plugged?And my dipstick wont go in now,it lines up then no movement. Do I have something missing, or what?
Old 09-25-2007, 10:03 AM
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I wish someone would respond I am having the same problems putting BBK shortys on my 97 lt1. I know I had to can one of the alternator brackets because that stud would not go through my header flange but there are three other mounting points and I drove mine after that and it was fine. As for those extra bolt holes in your fange the best thing to plug those up with would be bolts, my headers would not get a good seal to my heads without those extra bolts go figure. I still have a pretty nasty exhaust leak but I think it is coming from EGR and DS cat so I ordered a new gasket for the cat and that should be in today so I will let you know how that goes.
Old 09-26-2007, 03:43 PM
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I just put hooker lt's on my 94 lt1. The back bolt on the pass. side is a PITA. The headers had to go in from the bottom (remove starter and possibly steering linkage) with no issues. However, the o2 sensors on the headers don't look like they'll reach the plug (at least on the pass. side). What's up with that? And the AIR needs to come out because it's causing a serious vacuum leak! Otherwise everything went okay. And my y-pipe basically deletes the cat (I wanted it gone anyway), how are you keeping yours?
Old 09-26-2007, 03:55 PM
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Originally Posted by harner
I just put hooker lt's on my 94 lt1. The back bolt on the pass. side is a PITA. The headers had to go in from the bottom (remove starter and possibly steering linkage) with no issues. However, the o2 sensors on the headers don't look like they'll reach the plug (at least on the pass. side). What's up with that? And the AIR needs to come out because it's causing a serious vacuum leak! Otherwise everything went okay. And my y-pipe basically deletes the cat (I wanted it gone anyway), how are you keeping yours?
Call jegs and order the o2 extensions. Also I recommend using bandclamps with an impact!
Old 09-26-2007, 04:13 PM
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Originally Posted by Pntbll309
Well after taking a break, Ive gotten back to it but have a few Q's. The mount for the ALT that bolts to where the stock exhaust manifold was, does it have to be there? It doesnt look like a bolt will fit over my header flange. The extra holes where the exhaust manifolds had an extra 2 holes on each side, do those have to be plugged?And my dipstick wont go in now,it lines up then no movement. Do I have something missing, or what?
Take a break, it will take a few tries to get the dipstick back in but it will go. The holes dont need to be plugged. my alternator never has mounted to the exhaust manifold not sure what you are saying.
Old 09-26-2007, 04:14 PM
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Originally Posted by Pntbll309
Oh for sure, and the plugs...What gap does most you all go on some Tr55's? mods in sig.
Gap at .45
Old 09-26-2007, 04:32 PM
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For that PS ALT brakcet bolt I am having a good friend of mine bring some redi-bolt down and then I can make that bracket work for the ALT bracket.
Old 09-26-2007, 09:09 PM
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Originally Posted by Pntbll309
Well after taking a break, Ive gotten back to it but have a few Q's. The mount for the ALT that bolts to where the stock exhaust manifold was, does it have to be there? It doesnt look like a bolt will fit over my header flange. The extra holes where the exhaust manifolds had an extra 2 holes on each side, do those have to be plugged?And my dipstick wont go in now,it lines up then no movement. Do I have something missing, or what?
for your dipstick problem just buff it a little bit with some sand paper or buffing wheel.
Old 09-26-2007, 09:20 PM
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That I will do, I took the past 2 days off, havent felt up to it realy. I got 3 plugs, dipstick, air tube, and I think thats it, so maybe a few hours of work. Just gotta get off my **** and do it. While I was down there I gutted my cat too. Hopefully shell put out a nice rumble.


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