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View Full Version : Exhaust Header Fix for GT40P and others

fireguy50
08-27-2006, 12:06 AM
The last spark plug on the passanger side (#4) would not clear the header, others have had this issue with Headers.
Ford Racing 5.8L Truck Headers, part # M9430T58
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-problem1.jpg

I tried to add a dimple to clear the GT40P's lower plug angle, but it didn't work.
The dimple was doo deep for my aproval, and was still too close to the plug wire.
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-problem2.jpg

Here you can see the GT40P spark plug angle next to normal Small Block Ford plug angle
http://fordfuelinjection.com/bronco/exhaust/plugangle.jpg

Step 1) We cut off the collector from the primaries.
Step 2) We cut out the #3 cylinder primary section we intended to replace
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair01.jpg
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair02.jpg

Here you can see the parts we cut out:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair03.jpg
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair04.jpg
That stupid bung that was in my way:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair05.jpg

Step 3) Cut and fit a replacement tube (Stainless 304 pre-bent 45 I got from http://stainlessworks.net ).
Step 4) Cut the original primary up further and weld the 2 pieces together.
Step 5) Weld the piece back to the exhaust flange.
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair06.jpg

You have to cut further up the primary so you can weld between them.
You could replace all of the primary if you didn't like the bends.
fireguy50
08-27-2006, 12:06 AM
Step 6) Weld all the primaries back together before they are hidden inside the collector.
Step 7) Next you have to cut and grind the to fit the collector.
Step 8) Time to weld the collector back on the primaries
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair07.jpg
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair08.jpg
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair10.jpg
You can also take this time to clean up the welds inside the primaries.
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair09.jpg

Starting dimple problem:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-problem3.jpg
End Result:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-repair.jpg

We did remove the rear smog bung, it was late so we left the EGR bung, it's not in my way.
I'll get a picture of it on the truck Monday, with plug angle pictutres.
EZ SPEED
08-27-2006, 03:02 AM
Great Job !!! :chug:
QWKSNKE
08-27-2006, 07:51 AM
Nice work :nice:
SvoBrown
08-27-2006, 08:42 AM
Keep it simple. Good work.
fireguy50
08-27-2006, 03:41 PM
Starting problem:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P-problem1.jpg
End result:
http://fordfuelinjection.com/bronco/exhaust/M9430T58-RwGT40P.jpg
1sicklx
08-27-2006, 10:16 PM
:nice: Nice fix.
Dale McPeters
08-28-2006, 02:57 PM
Good Job Ryan....:chug:
ncontt
08-28-2006, 07:19 PM
holy crap....that a way....show that header who's BOSS..;) nice job
Italian LX
08-28-2006, 08:10 PM
Nice work, Ryan. :nice:
natedawgg94
08-29-2006, 07:36 AM
way to adapt and overcome looks great man.......:metal: :metal: