Well, I decided to get the Summit headers for my '99 5.4. 2 studs had sheared off on the pass side manifold and the leak was driving me crazy.

I got the headers for $170 from Summit including shipping (they have a PaceSetter tag and EO # right on them). I ground the collectors out to 2 1/8" as it was about 1 7/8" out of the box, wire wheeled & sandblasted them. Then painted them inside and out with POR20 aluminum coating (great stuff!!). It's good for 1400 degrees. I baked them at 450 degrees for about 15 minutes between the 1st and 2nd coats and for 30 minutes after the 2nd coat, so hopefully it last for a long time. Total cost with Felpro gaskets, better bolts & washers... around $220.

Here's a pic of the new dr side header and the factory manifolds (amazing how much they decayed in 5 years).



Getting the factory manifolds off kinda sux, but with these Sears bolt/nut extractors it was possible. Note, buy these first (the #7 unit is what you need) or you'll never get the studs/nuts off. I was really surprised how rusted mine were. I used a 3 foot 1/2" drive extension as a punch and a 3lb hammer to drive the extractor onto what was left of the nuts. They all turned right out.


Here's a couple pics of them installed. I broke the dipstick tube trying to get it out, so I haven't fired it yet. I'll probably bolt everything else back in, fire it up then stuff the dipstick in tomorrow so I can drive it. I was leary of these relatively cheap headers fitting, but the fit itself is nearly perfect. All the bolts went right in and the flanges for the Y pipe are dead on. The only gripe is the EGR tube was off about 5 degrees but that's easy to tweak. The welds aren't the prettiest, but I can live with it considering they'll be under the hood.



Steve

 

Hope they work..

 

 

i have been thinking about getting a set of these, how did you paint them on the inside and how did you bake them? in your oven at home or what, and were did you get the aluminum coating? thanks for your help

 

 

The paint/coating is POR-15's high temperature POR-20 product.POR-20

I used an HVLP spray gun to apply it (I have a decent compressor and use to work in a body shop and was an engine machinist through college). Basically, to get the insides coated, I blocked 1 end of each pipe, turned the airpressure up, reduce the paint flow and turn it to the tightest stream I could. Then, when I'd blast some into each end of the pipes to get till the insde was covered. To bake them after the first coat, I fired up my wood burning stove in the garage. I happen to have a infrared temp gun (for taking tire temps on my circletrack car) so I could monitor them to make sure they got up to temp sitting on the stove. After the 2nd coat, I let them sit for 24 hours, then baked them again in the garage for about 10 minutes to get the smell out, then stuffed them in the kitchen stove for 20 more minutes at 475 degrees.

And I'll add that the install isn't too hard with the bolt extractors, a cutoff tool for the Y pipe bolts and some really nimble fingers. Oh.. and alot of patience. I spent 3 nights (3-4 hours each night) getting them on. I fired it up tonight and there's no leaks. Coating seems to be ok too. After running for 25 minutes it would have burnt off if it was going to. Now I just need that new dipstick tube (tomorrow) so I can see if it added any power.

 

thanks for the info

 

Did the gaskets you bought come in 2 pieces for each side?

Or can you tell us which ones you ordered.

I ordered Fel-Pro exhaust manifold gaskets and they came in 2 pieces for each side.

The gasket which came with the headers was one piece per side, but cheap *** paper.

Thanks for any heads up.

 

Would you consider doing this for someone else (minus the paint work)?

If so let me know how much you would charge, if not I understand.

Thanks

 

Hey did you remove the fenders or something? It seems like an awful lot of room in there.