JPFreek 0 Posted February 3, 2011 It's been too long since I last logged in to check this rig out and wow...nice job Diane! It's looking awesome!! Let's plan to do a Freek Show article on the vehicle in our May-June or July-Aug issue. Cool? Share this post Link to post Share on other sites
OLLIE 1 Posted February 9, 2011 Incredible build and great documenting. One of the better build threads I've ever seen. I love your XJ. Share this post Link to post Share on other sites
dzJeepChic 2,897 Posted February 12, 2011 I need to back up a little bit to the Header Installation for which the write up was delayed. After purchasing and returning a 'No-Name' header which didn't line up with the header gasket, we went out and got a smoking deal on a Pacesetter Header. We went straight to the manufacturer here in Phoenix, talked to a guy who let us come in and take one out of the box to compare it to the correct header gasket. It matched up perfectly and he offered us the aforementioned smoking deal, so we bought it. The installation begins. Intake manifold must be removed along with the exhaust manifold G said the intake tubes were all full of gunk & he used the opportunity to clean them out And he cleaned all of the carbon out of the intake manifold Everything was smooth sailing until he was ready to install it and noticed that the header gasket that came with the header didn't line up with the intake manifold. Pacesetter had included the gasket for a later model XJ with larger intake ports So George he had to run to Checker, er, OOOO'Reilly's for the correct gasket Gaskets compared: Top is wrong one that came from Pacesetter with the header, bottom one is correct one that George stopped working, washed-up, got his wallet, got in Number 7 and ran down to the parts store and purchased. You know what I'm talking about, right? Let's just say I learned a few new vocabulary words. The new gasket installed; perfect fit George sanded off the little bit of burrs that were on the flange The header is finger-threaded on Continued V V V Share this post Link to post Share on other sites
dzJeepChic 2,897 Posted February 12, 2011 The new header flange is thiner than the stock one so it came with these machined spacers The fuel injectors are in the intake manifold, so while he had it appart, George soaked the injectors in Lucas Fuel-Injector Lubricant/Cleaner overnight and installed new O-rings From here it should be all downhill, but this is really where the fun all began. The header kit includes all the pipe ready to bolt on to the catalytic converter and it has a re-positioned O2-sensor bung-hole, which, after the O2 Sensor was installed, hit the hard transmission lines. Plus the header down-pipe rubbed against the transmission bell housing The header down-tube was bent too much toward the cross-member So he had to do some cutting and modifying what the Pacesetter Header came with to make it fit. Starting with the down-tube Continued V V V Share this post Link to post Share on other sites
dzJeepChic 2,897 Posted February 12, 2011 First he had to relocate the O2-Sensor bung-hole and fab in factory flanges G's homemade exhaust which includes a flex-joint so the header is less likely to crack due to stress Installed He used header wrap since it's right next to the transmission, trying to keep from heating it up So far we've been on a couple of day trips and one highway trip and the exhaust is functioning perfectly. It's too bad there were so many installation issues with the Pacesetter Header. We called them to discuss the issues we ran into, and they replied with the old "We've never had that problem before" bit, and made George out to be the dipstick. Everytime we've called a manufacturer with a constructive critisism we get this 'We've never heard that before', 'We don't know what to tell you' kind of response. It's too bad they don't want to learn from their customers' experiences, especially when we're willing to show them exactly what was required to make their product work.Anyhow, that's my Header Installation Story and I'm sticking to it. d Share this post Link to post Share on other sites
klaykrusher 65 Posted February 12, 2011 Great work George...I don't know how you keep a sane mind with some of the issues you've run into.... Share this post Link to post Share on other sites
dzJeepChic 2,897 Posted February 12, 2011 Great work George...I don't know how you keep a sane mind with some of the issues you've run into.... Who said he's of sane mind? d Share this post Link to post Share on other sites
klaykrusher 65 Posted February 12, 2011 Who said he's of sane mind? d I was trying to be optimistic.....LOL :rolleyes: Share this post Link to post Share on other sites
GRUNT 111 Posted February 12, 2011 Great update. I like the flex idea. Share this post Link to post Share on other sites
OLLIE 1 Posted February 12, 2011 George is one talented man. Great recovery. Personally, I think those machine spacers that came with it look like s**t. That in itself is an example of poor craftsmanship. Share this post Link to post Share on other sites
