I'm thinking about selling them I'm not sure. Tomorrow a few of my co-workers and I are going to modify them. If we can get a torch in there we are going to heat that crossover pipe till it'* red hot and then bend it the right way. Otherwise I think we may just put a nice cut in the pipe and then weld up the open area once it is sealing correctly; but that will mess up the coating :( . Either way this is complete bull, I shouldn't have to hack these up like this when I spent $900 on them.

I didn't get a darn thing done today, here is what I'm up against with these headers.





I’m going to look on ClubGP later and see if I can find how other users have dealt with the situation. Maybe even try to get in contact with TOG but I doubt that would go anywhere.

I'm so close yet so far away.

Ed

You're the only pre-2000 Bonne with TOG'* correct? Really stupid question and I can't remember what the entire exhaust set-up is like, but is there any way to adjust the exhaust angle or something AFTER the headers so that things line up?

L32 head configuration is the same I thought. I dont see why they dont fit unless the headers are defective out of the box.

I bolted down the rear crossover flange on my TOGs first, since it was much harder to get to, then I did the front. I didn't really didn't have any issues.

The L32 heads are the excate same as the L67 ones. I'm pretty sure Foghorn as the same headers on his car.

I've tried everything with these. Leaving the front and/or rear header and tightening down the crossover then tighten the headers to the head and so on. I read on ClubGp somewhere about TOG making some sort of change and now all the set are like this :? I'll get it figured out but I'll probably have to hack up that crossover pipe and ruin some of the coating

For $25 more I could have gotten the ones with larger primaries, I've been thinking if I had bought those would I still have these issues with the crossover...

Ed

You had them on before w/o any problems right?

No that crossover was a real PITA last time.
This time it seems worse so I'm going to try to fix it for good.

Ed

Today we addressed this header issue. I’m much more relaxed today. I was so close to buying a pair of SLPs and selling these TOGs (someone almost got one hell of a deal, lol) till my co-worker Rex told me he could fix them no problem.


This is what we came up with…

Put a nice slice into the rear header under where the crossover pipe should meet.


More of the cut.


Bolted the headers and crossover up allowing, the collector for the crossover to move as necessary. We had to do this 2-3 times every time we would remove the rear header we would adjust our cut in the header widening it ever so slightly each time. Once we had it dialed in Rex welded as much as he could with it on the car. Once it cooled we unbolted everything and ran a full bead off the car.


Finishing the welding. We sprayed some ceramic paint on the header over the weld while it was still very hott baking it on instantly.


All bolted up now & this is how the front of the crossover is sealing.


Rear (size of the sealing lip on the rear of the crossover is not uniform so it may look far off but its far from that.)


Almost there!


I’m hoping to be able to turn the key tomorrow! All I have to do is hook up my heater hoses motor side. Rad. Hoses, Rad fans, fill with coolant, install pcm, reinstall STB, play with my TB a little & double check a million things.

Say a prayer for me and my baby!

Ed

Everything is ready to start her up! Except for the fact my brand new starter is dead I pulled it off and bench tested it, the gear kicks out and thats it :( . The parts store I bought it from is now closed and won't be open till monday to exchange it. So back to the house I go, I'll post some new pics when I get there.

Ed

I modified the barrel at the end of the throttle cable to work with North Star TB. I didn’t want to modify the TB itself since that cable is cheaper (or I think at least). At the very right of the pic you'll see my little brass plug I made for the Evap hole on the Gen5.





Vacuum port on the TB hooked up for PCV functions.




I just had the plug wires thrown over the motor since I wanted to start it up but in this picture I was all ready to go.





Such is life I guess, I also stopped in a the local GM dealership and they want $92+tax for a Case Lean.... And thats if "everything goes ok"


Ed