Question for You Who've Installed Thunderheaders
 

What's the best way to get that damn header clamp on there that goes over the rear pipe? I got it on at the head, but now it's the question of trying to get it around the O-2 bung, and I'm really trying not to tear the paint up in doing so. The damn thing didn't need to be made quite as tight of a fit as it was...it could still have been clamped down a bit extra and been fine. Help?!

OK, I solved this bracket problem with a jackstand and a ratchet strap actually....but my problems have gotten worse.

The flange nuts are stripping and I can't get them back off to replace them. How do I remove stripped nuts from flange bolts?

Sounds like your not doing to well over there man. Sorry I can't really help ya out, but if its any consolation to ya, those pipes were in PITA to put on!!!! Very, very tight fit. Good luck though! I hope it works out for ya man.

Yeah man, definitely a way bigger pain to install than I expected. The only problem now is those flange nuts....I hope I can get them off because I don't know what the hell to do if I can't. I'm open to suggestions everyone!

so right now the pipe is on the bike ,but, the nuts just spin? how many nuts we talking about here? also when installing my pipes I noticed that the nuts would tighten a little while pressing into the flange, the flange then seated better and the nuts were loose again. Any possibility this is what you are experiencing?

the flange nuts that hold on the muffler?take a break your just getting frustrated and that makes a bad situation worse

i would get a can of break free clp soak em good and let them set over night,
i use it on everything my guns included it has properties that allow it to soak into the metal
i have a closet full of rust free guns because of it if all else fails drill out the flange bolt or if you got bolt cutters snip snip problem solved
you''ll need some new flange bolts though:)

sounds like you do already though

Nah, the flange nuts are tight and I can't get them back off...the socket was starting to spin over them. I quit before I forked anything up worse, so I think all 4 are like that, but am not sure...I haven't had time to get back in the garage today.

Yeah, that's why I finally called it quits last night...I was being persistent because I was frustrated and tired, and although I didn't want to stop, I knew I needed to.

How hard is it to replace the flange bolts? I don't have my service manual with me, but I imagine it entails getting into the motor itself....probably something where I'd just take the heat and let the HD wrench handle it.

:(

just try to back em off and if they break, hopefully there is enough left to use a stud remover.
i would think that if anything, the stud will just back out too.
repl with a grade 8 stud.
fueling has em
did you use antiseize?lol

Maybe try to tighten another nut against the one that won't come off, then try to back the original one off with what ever you can get in there, I know there aint much space but worth a shot. When you do get em off use this same method to take the studs out of the heads to replace with new ones.

Hadn't fired the motor up at this point, no anti-seize yet. I was just checking for fitment more than anything, they need to come back off for header wrap.

I noticed how that worked, tightening one against the flange and then the other would loosen...my concern at this point is that with some already not backing off, that I might end up torquing them up too much and be even more messed up. I really don't want to have to go to HD for this.