So I bought the MSA Header kit (Motorsport! MSA 3-2 TBC Coated Header, With Smog Fittings, 79-80 280ZX - The Z Store! Nissan-Datsun 240Z 260Z 280Z 280ZX 300ZX ( Z31 Z32 ) 350Z 370Z Parts) and after finally getting the header installed, I tried to put the second pipe in place, and discovered that either the two pipes from the header are too close to each other, or the two pipes on the second one are too far apart.. it's off by about 1/4" and won't go on..

Is this normal? what have you guys done? I'm concerned that if I squeeze the two together or spread the two from the header, it will **** up a weld somewhere..

 

Pics would be helpful.

 

I talked with the Z Store (super friendly customer service, they've been great..) and they think I should be able to just muscle it on, but I'm a small dude and not seeing how to get the pipes to bend without damaging them..

I also put a micrometer on all four (checked inner diameter of the larger, and outer diameter of the smaller..) and while they SHOULD fit, I can't seem to get just one pipe to slip on (rotating it so the other pipes aren't connected, just trying to test the slip fits...)

One of the attached images shows how the bottom looks with the top lined up, the other is bottom lined up..

I did the best I could laying on my back, supporting the pipe and trying to take a cell phone pic..

 

That doesn't look bad at all. I would just strap a come-along on there to bring them together, or use a prybar to gently widen the header side.

 

I tried using a ratchet strap, but the hooks were too big and i couldn't get it to have any impact on the pipes.. worried about prying because i'd hate to deform any of the pipes. the fit tolerance is already so tight, i feel like any tweak would make it not fit at all..

I think my best bet is just gonna be to shell out cash to someone to finish the install instead of being that guy every mechanic hates, "yeah, i almost got it, but now it's ****ed up and i need you to fix my mistakes.."

 

**** it, who needs a catalytic converter, muffler or exhaust pipe?

 

Had a local Meineke finish installing the pipes..

The exhaust kit was designed to be used with the delete pipe, the catalytic converter was about 3 inches short so they had to fab that into place, and they agreed with me that there was no way that the header pipes lined up with the exhaust pipe, they said it took them a few hours or heating and prying to get them to line up.. That's not the kind of headache I expect for such an expensive system, but whatever, it's done now and the car is running fine. Passed Virginia state inspection so the kid can drive now..