ZZperformance shipped my headers on Friday so I have a bit of time to get ready before they show. What will I need to do this? I have the trans dip stick and tube comming with the headers but is there anything else (gaskets etc)? Should I block off the egr now or wait and compare the difference with and without? I still have to find a shop with a lift and a welder in this small town but hope to have the headers installed before the new year.

I would do the EGR blockoff as soon as possible, and it will be easier with the header not on the car. You don't have to break open the engine very far to see how filthy it makes everything. The headers should come with everything needed. I seriously hope you aren't planning on putting them on yourself though, it is a PITA and you really don't want to. That is the only thing we didn't install ourselves on the GTP, and it took the people that did it like 8 hours to get them on.

Shawn

the header is not hard at all to do yourself. it only took me and a friend like 7 hours to do and we were taking our sweet time to make sure everything went smooth. luckily my friend had all the tools needed (including a car lift) in his garage.. but either way i can't wait to see the smile on your face when you get them on.enjoy.

Yeah I'm doing the install myself, I have all the tools and a torque wrench too and I'm pertty handy being a tradesman.
I looked on line at the egr block off plate and thought I could make my own? looks like a block of steel with a hole in it? Does anyone have the dimensions they can share?

You could definately make one yourself, but personally it isn't worth it IMO since it is only $5. You would have to get the aluminum (I'm pretty sure it is aluminum), cut it to size, and tap a threaded hole in it, and it seems easier to me to just buy it already made. I can get you the dimensions for it if you want, I don't know them off the top of my head, but I wll get them for you, but I would seriously just buy it. But, I'm also lazy, so that could be why.

Shawn

Its not that im cheap or overly eager but I did forget to include the egr when I ordered from zzperf. and ordering one now would be to late for my pending header install later next week. I have stock aluminum at work at the time to drill and tap myself. Thanks Shawn if you can get me the dimensions that would be great.

Brought a few items home from work today, 1/4" thick aluminum plate 2"x2", Taps -standard and metric, drill bits and penetrox (agent used to join to dis-similar metels together)
When I get the headers I'll build the block and cover the egr tube. Do I need a gasket?

You don't need a gasket for it. I am sorry, I completely forgot to get the measurements for the blockoff plate for you, so I will do that.

Shawn

I formed a gasket using an old header gasket but any high temp gasket material will work.
I also smeared a little bit of red high temp rtv sealant on one face for a leak tight seal.

I hope you also use a proper filter on the egr tube end.

Let us know how the rest of the header install goes......you lucky dog.

silverbullet said:
I'll video tape the whole install for ya. Then I'll ftp it for you on the company site (Canfor). I hope to have this done before the new year. I'm takin out the cat too since theres no need for air care up here.