header install
 

So I had a cat. I decided that it was restricting my power and I got a Downpipe from Mel. Turns out that it sat at a weird angle and Kept leaking right where the header mounts to the downpipe (you can see where it kept getting loose and leaking compared to the new header)

http://i20.photobucket.com/albums/b2...2102007168.jpg

I opted to get a SS header by BBP 4-2-1 single piece. Construction is pretty cool The welds look good.
http://i20.photobucket.com/albums/b2...2092007159.jpg
http://i20.photobucket.com/albums/b2...2092007160.jpg
http://i20.photobucket.com/albums/b2...2092007161.jpg
http://i20.photobucket.com/albums/b2...2092007162.jpg
http://i20.photobucket.com/albums/b2...2092007163.jpg
http://i20.photobucket.com/albums/b2...2092007164.jpg


I took it to a local shop to get the EGR bung welded up. I forgot to take a before picture of the header (OEM) but i'm sure u guys know what it looks like.
http://i20.photobucket.com/albums/b2...2102007168.jpg
(you can see where its welded up at the EGR)

First off you're going to have to remove the heat shield ( i didn't have one so no need there).

Next i'd recommend using WD-40 or something to break soak on through and loosen the nuts. (there's 8 of them on the manifold connected to the block and then 2 where the cat is connected and 3 where the header and down pipe connect).

i removed the 8 nuts on the motor (14mm) - it's really easy w/ the stock mani, the new one is welded so u have to use a ratcheting wrench to tighten the bottom nuts when you the new one on.

http://i20.photobucket.com/albums/b2...2102007171.jpg

(don't forget to unbolt the 2 bolts holding the DP to the dummy cat)

Here is a pic of the new gasket (1piece) vs' the old gaskets. The new one was very impressive and included with the header, all metal, pretty thick and fit like a glove. (you can also see the where the 8bolts are)

*when removing the gaskets you might have trouble w/ the cyl. 1 gasket. There is a spring that holds it down (far left bottom bolt) so i just cut it.*

http://i20.photobucket.com/albums/b2...2102007170.jpg

what I did was take off all the o2 sensors and put them on before i put the new headers in.. Do it anyway you like but it's easier when its not on the car.

http://i20.photobucket.com/albums/b2...2102007169.jpg

Now just slide the new headers in and bolt up in reverse order. plug the sensors back on in and you're set.
http://i20.photobucket.com/albums/b2...2102007174.jpg
http://i20.photobucket.com/albums/b2...2102007173.jpg

Just a side note: i'd recommend unbolting the header from the DP (since the oem s14 one has a huge ass cat on it, it's hard to pull up as one piece). When you unbolt it u can seperate the top and bottom pieces.

*power gains not so significant, BUT the powerband is a whole lot smoother. and the sound is a much cleaner and out the tail pipe minus that exhaust leak I had.

Question, why aren't you using the OE nuts/washers? Just curious.

sweet. I did the same thing but with a s13 manifold and downpipe.

project RDM, i thought those were the oem nuts. They were what were on there when i got the car.

it might be the oe nuts, but it comes stock with thick metal washers. i reused those on my header install.