Hey
my new Header, won’t fit in the Head’s Exhaust Ports,…. Like the pipe was formed too “Narrow”. Don’t matter if you start with Rear Port, or the front. The pipe is too narrow to fit in Both. 😟

tried many time on Saturday Afternoon, till dark. Won’t fit.
so,… shut down the frustration and go to bed.
Sunday:
(no, still won’t fit) I measure the stock headpipe, and the ports are 3/16” wider,…
😳
hmmm,…. What to do, What to do,…?
ahhh small floor Jack!!!
I padded the header with a towel, and started spreading the ports apart with the floor jack,…
add some pressure, then measure, then try again.
took 4 times, but I added ¼” the the spread between Front/Rear,…..
slid right in with No Issues.

I just thought I’d share my frustration,… I’m better now.

 

So, did you get it all together and no exhaust leaks? That's the final end game, right?

 

if you didn't have to force it a tad you may have leaks.and drawing it up with the nuts may break a stud.

 

Wow... that IS some frustration....

I would never do that to a new header.... I'd call the manufacturer suspecting the wrong head pipe was sent, before I'd modify it myself and lose any chance of the manufacturer making it right...

I forget what bike it was, but I had a helluva time getting a head pipe on, I believe it was a Bassani on my 2003 Heritage. I finally walked away, and went back the next day... I then angled it up, slid it in front then back, and angled it back down... all in one smooth move in about 20 seconds... I was glad I walked away, gave it some thought, AND calmed down..

I hope your "mod" works out .....

 

Had that same issue when I put my pro pipe on , tried for 2 hrs before I did some research , seems you have to hold the bottom of the exhaust outwards on an angle while slipping the port ends in , not much room , but finally slipped in .