From doing searches before I got my headers, I saw that the #1 primary slip fit in many headers is a hot topic for debate. I didn't like the idea of putting an unsightly clamp on my shiny new headers, and I didn't think that copper RTV would hold very well (and it would look like crap anyway). Here's my solution:

First of all, I tested out my slip-fit with the headers off the car and was dismayed at how loose it was. I stuck the primary all the way into the header and moved it around so it scratched the coating a little. That way I knew how far it went into the header (plus you can't see the scratches once its installed). Then I took the #1 primary to a local muffler shop (I went to Tuffy) and had them expand the end very slightly. They expanded it just enough that you could see a difference at the end and feel the increased diameter. They didn't even charge me and were pretty cool about it.

Then I went to AutoZone and picked up THIS stuff. Sorry for the blurry pic, but you get the idea. Its called ThermoSteel and its made to mend exhaust manifolds and headers. I mixed it up like I said and then put a good amount of it on the end of the primary where it had been expanded. By this time, the header was on the car, and bolted up tight. I aligned the primary, and beat the crap out of it with a rubber mallet until it slid into place and I could bolt it up.

HERE is a pic of the final result. I think it was a pretty clean install, the ThermoSteel dries to the same color as the header. Just make sure that you clean up the extra that leaks out IMMEDIATELY cause it gets harder than all hell. I haven't noticed any leaks so far, and I would be surprised if I ever do. Hope this helps some of you out there fighting the problem of the slip-fit.

 

interesitng, mine sealeditslef, i have leaks or nothing there, and i didnt do anything to it

 

looks good, I used the unsightly clamp and RTV method,

Brian

 

Thats a fine and dandy fix until you need to take it off. My buddies jet hot coated long tubes had a slip fit primary #1 and they came so tight we could not get it in with out taking a burr grinder to the inside of the pipe. Got a nice tight fit that still allowed us to put it all the way in. No leaks.

 

I guess it all depends on how your headers come. I got Jet Hot coated Hookers and the slip-fit was so loose that I could wiggle the primary around in the header. It was pretty bad, so I did what I could.

 

that makes sense, just thought it might make it a little difficult to take them out, if you ever had to

 

That's a valid point, never really thought about it. I don't think it will be too much trouble, though. My driver side slid right in, so with that #1 primary still on there, I'll probably have to jack up the motor on that side like I had to on the passenger side. I'll cross that bridge when I come to it

 

I never did anything to mine... It never leaked and still doesnt to this day. It has been a year now..