I started installing a Thunder Max with Autotune on my 2007 Ultra Classic.

I am replacing my PCIII because I like the idea of no more dyno time and I got it as an early Christmas present from my wife.

I have Vance & Hines True Dual Headers.

Right away I have the problem with rear O2 sensor hitting the top of the transmission cover.

I have searched on the HDForum for information.

I’ve seen several references to this problem with suggestions.

I would like to heat the pipe and bend/tweak the rear O2 bung to allow for proper clearance.

Questions:

Can someone who has done this give me a clear 1, 2, 3 type explanation on how to do this?

Will a torch like you use for plumbing get it hot enough?

Do you screw the old spark plug or bolt in before or after you get it hot?

How hot is hot enough? Will it be glowing red?

How do you do the bending?

Put a pipe over it? Hit it with a hammer?

Can you do all of the bending at once? Or, heat bend, heat bend, etc?

How will I know if I have created an exhaust leak afterwards?

If I crack around the port, can I have it repaired or is it toast?

Pictures would be great, but any help or explanation would be greatly appreciated.
Thanks in advance.

 

I have none of the answers nor any info you seek but... That is probably one of the best constructed question/info requests I have ever read on any forum. I predict you will get all the input you need.

 

Are these slipns? if so you should not have this problem. I haveaspare header pipe from my -7 RKC available, think itwould fit, have the D&D 2-1 so dont need it, alsohad the Tmat installed in this header no prob with it touching the trans,. Are you using a crows foot socket?

 

Sorry just reraead your post cant help you as I am not familiar with these pipes.

 

These are Vance & Hines True Duals, not stock headers.

 

I would put another bung in, I don't think you will be able to bend the bung and pipe to get where you want, It will get cherry hot but when you go to bend the pipe may collapse or kink, if you do try this take the pipe off. I would Plug the old bung hole, they sell plugs for this and drill and weld a new bung in, you will have to take the pipe off to do this, just make sure you mark the spot where the new bung has to go. I had V&H drilled and welded for the sensors turned out ok. I then decided to go with the new Bub 7 true duals, already have the bungs in, perfect locations. Just my thoughts.

 

I have this setup on my '07 SG and had exactly the same problem. I put that section of pipe in my vise, took a flat-end punch and "dinged" the pipe directly behind the bung so it would weaken the pipe at that point. Then I put the pipe into the vise so it was clamped on the pipe on one side, and the edge of the bung on the other. I had made a block of 2x4 with a groove in it so the pipe wouldn't flatten when i squeezed it with the vise. I then tightened the vise so that the bung started bending the pipe where I had "dinged" it. I took it out and ran the old O2 sensor in and out to make sure I was not causing the bung to become oval, then put it back in and clamped some more. Took about 3-4 times to get the bung to tilt some by creasing the pipe the tiniest bit. I now have about 1/4" clearance between the newer, longer O2 sensors and the tranny cover. Pretty low tech, but it works and I don't believe I've affected the flow in the pipe, as it barely pushed the pipe in to get the bung moved enough to make the difference I needed.

Too bad V&H didn't just rotate the bung a 1/2", would have alleviated the problem in the first place.

BTW, just found another guy that did something similar, but heated the pipe. Here's the post:
https://www.hdforums.com/m_1762485/tm.htm

 

I sure would like a little more detail on heating and bending the pipe.

Thanks in advance.

 

Still looking for a little advice.

Anyone?

Thanks.

 

Your going to need a torch heat around the bung until it's cherry red then us a punch or something else an stick it in the bung hole and bend it to where you need it. But for what its worth I would buy a set of D&D pipes and be done with it. I had researched this myself and this would be the easiest way. Sell the V&H on e-bay.