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mtweller · 04-08-09, 09:01 PM

My $.02 on the header is to scrap them. I have dealt w/ exhaust leaks for quite some time due to a header. The 6-1 flange is too long and will warp with time. I've had mine machined flat a few years back and it is leaking again - and I drive it VERY little. I took Marshall's (Trollhole) advice and sourced a pair of FJ62 manifolds. They can be see here on the Big Gay 2F writeup:

http://forum.ih8mud.com/40-55-series...d-tech-10.html

Look at post 287. You'll have to get a bit of exhaust work done to tie the two manis into the main exhaust flange, and you'll have to grind the intake manifold for clearance (nothing too challenging), and you'll need to cut the bolthead recesses to match the thickness of the intake flange (I have a method that works and doesn't take too long):

http://forum.ih8mud.com/40-55-series...0-headers.html

I just did this this weekend and while it proved to be a bit challenging due to broken studs, I shouldn't have to worry about exhaust leaks again for a LONG time.

Let me know if you want any additional info.

R

04-08-09, 09:01 PM	#3 (permalink)
mtweller Olde North State Cruisers Join Date: Aug 2005 Location: Morrisville NC TLCA# 5314 Posts: 1,442	My $.02 on the header is to scrap them. I have dealt w/ exhaust leaks for quite some time due to a header. The 6-1 flange is too long and will warp with time. I've had mine machined flat a few years back and it is leaking again - and I drive it VERY little. I took Marshall's (Trollhole) advice and sourced a pair of FJ62 manifolds. They can be see here on the Big Gay 2F writeup: http://forum.ih8mud.com/40-55-series...d-tech-10.html Look at post 287. You'll have to get a bit of exhaust work done to tie the two manis into the main exhaust flange, and you'll have to grind the intake manifold for clearance (nothing too challenging), and you'll need to cut the bolthead recesses to match the thickness of the intake flange (I have a method that works and doesn't take too long): http://forum.ih8mud.com/40-55-series...0-headers.html I just did this this weekend and while it proved to be a bit challenging due to broken studs, I shouldn't have to worry about exhaust leaks again for a LONG time. Let me know if you want any additional info. R __________________ "Ramon" Weller '78 FJ40 - Dune Beige - SOA (FJ55 rears, flipped fronts), SM465, MT Tube Fenders, MT Family Cage, 35x10.5 BFG MT, Aussie Rear, ARB Front, Saginaw, 8274-50, homebrew bumpers Olde North State Cruisers - "And if I die in Raleigh, At least I will die free"