I'm also a little worried because the primaries are really close the frame on both sides, less than 1/4"

 

on the driver side i took off the heat deflector that was mounted to the cab and i was able to get the rear bolt. Hopefully you did not strip the threads but it sounds like you did. you may be able to rethread it. if you can get the other bolts in and that one that you think is cross threaded it tight enough so that it doesnt leak i would just leave it alone unless you have a problem later. mine were close to the frame but i dont think they were that close. did you put anti seeze on the bolts before threading them in

 

Yes i put anti seize on the header bolts and spark plugs.

I thought about taking that heat shield off but it looks like a PITA. Realistically my goal today was just to get evertything in and running. I got that. I dont need to drive my car this week so I think I can work on it next weekend.

With all my leaks and whatnot, what is the possibility of carbon monoxide getting into the cab?

 

Copied and pasted from our PM....

Ugggh, does not sound like a fun time...

Here's what I would do,

For the cross-threaded bolt, pull it out and re-tap the threads before any more damage occurs.

Check Engine lt with the key on is normal, as is the moisture from the tail pipe, especially with new exhaust components on there. The truck may run like poop with all of those exhaust leaks, as unmetered air is entering the exhaust and throwing off the O2 readings.

Not sure as to how much carbon monoxide would escape and enter the cab, but with the leaks, it will run richer as the PCM compensates, and that can't help the CO situation...

 

At the very minimum I don't want to drive it until I get the header leak taken care of. That's the big one to take care of. The other leaks are minor and can be taken care of pretty easily.

 

What other leaks do you have?

 

As far as I could tell (I just checked briefly) I have NO leaks where the collector meets the Y pipe. I sealed those very well. I am leaking from where the pipes just slide into each other. The clamps that came with the kit aren't the best and I'm thinking maybe I should get some better ones. One of the clamps is in such a horrible position though because it's right above the crossmember so it's really tough to get to. My goal right now is to take care of the header leak. Everything else is post 02 sensor so it's not a big deal. I should also note, I don't have a good seal at the flange between the end of the OBX pipe and the stock catback. When I had my magnaflow muffler welded in I believe he changed the geometry of the pipe such that the holes on the OBX and the catback flange do not align properly. I can fix it easily though and I only have 1 bolt in it right now because that's all I had. I forgot that the stock Y pipe has the screws welded into it that attach to the stock catback

 

i ran into the same problem with the y- pipe. but my 08 has a flew joint right there so it worked out i just had to buy some bolts and nuts to bolt it together . also the clamp that is above the crossmember if you have a universal joint extension for your wrench set you should be able to get to it.

 

Ok, I have all the bolts in on the drivers side EXCEPT the last bolt.

Guys, how do you deal with this smell? I'm going to wait until I get all my leaks taken care of, but its so bad I'm thinking of going back to stock

 

Good and bad news.

The hole that I thought was crossthreaded wasn't. The screw was banging up against the hole on the header flange making it hard to screw in. I got everything bolted up as good as I could. All header bolts in except the very last bolt on the drivers side. Started it up and it didnt sound like it was leaked too bad.

So I just went for a drive. HOLY ****. Whoever said headers lose down low GTFO. I only went up to 2500rpm or so, but the difference over stock is amazing.

The bad news is that my passenger side header is banging up against the frame. One of my wires was also burning due to the hump on one the driver's side primary.

Also, the smell. My god, how do you deal with it?

Tomorrow I'm putting all the stock **** back on and ordering some pacesetters and 2 hi flow cats. I was just going to go back to stock and stay with it, but after feeling that power, wow.