Alright if anyone was following my other thread, I posted how my used MAC headers didn't line up to the bolt holes on the passenger side.

Well I was able to file it out so I enlarged the holes so they do line up now, except for the 2nd bolt hole on the passenger front of the engine (read as, right above the #2 spark plug)...

If I leave this bolt out, will I develop a header leak? How about if I goo it down real good with the RTV Gasket? I have no idea how I'm going to make it fit otherwise, as I can't really make that hole bigger as it's very close to the primary tube....

 

You could either have the tubing bent to match at an exhaust shop but that might make the problem even worse. I would suggest getting the hole welded up, and re-drilled.

 

I was thinking about this and possibly I could file all the other holes wider so I could slide the headers forward that 1 centimeter (or less) to make them all line up? I can't believe this, that the headers warped with the previous owner and don't line up....This has given me a problem for like three weeks. *sigh*

 

If your flange is warped causing the hole mismatch your never going to seal. If it was me I'd bite the big one & buy a new set of headers! Working on these cars is a pain & leaks will make more work.

 

Well it's worth a shot right? What would cause the headers to warp?

 

are you sure that you are using all of the right bolt holes? because there are sort of 2 choices of bolt holes in the heads. - maybe someone could provide pics.

 

Sell the headers. You are wasting your time.

 

I agree. Headers tend to warp a little bit as they get older but if it's so bad that you can't get a bolt in then I suggest buying new ones.

If you do get new ones get a Felpro gasket and line it up to see if it matches before trying to install it.

 

Well now i know not to buy used headers. I think I'm gonna file the holes so they widen up and all fit in.

I know what you mean about more than one hole, but trust me, I'm using the right ones.

If these give me a problem I'll wind up getting new ones and selling these headers. I can deal with a header leak for a little while (if that's what happens).