Originally Posted by .boB

This is a pretty common problem. Studs appear to be easier, but they're usually a pain in the neck to get the flange over them. Not many people use them.

Get some header bolts from Summit or wherever. They have a smaller head, usually 3/8". I don't like 12 point heads for this application. You can only use a box wrench. Often there isn't enough room for a box wrench.

SOmetimes the bolts are too long, and hit the header tube if it's curving in that direction. If you tighten down all the bolts, you'll find that bolts hits the header tube and you can't tighten it. If that's the case, start by screwing them in only half way. Then go back and tighten them the rest of the way.

I use split lock washers, and I never have trouble with them coming loose; I don't know why, as so many people do. But you might consider one of the mechanical locking devices.



I agree. But I do use one stud to help with installation. I use a bolt with the head cut off, and screwdriver slot cut into the end. I put it in the first hole, and then put the header flange and gasket over that stud. That keeps one end in place while I get another one started. Makes the job a lot easier.



Tack weld the head of the bolt to the flange. A simple tack will keep it from spinning. But easy enough to grind off if the studs breaks or strips. A star washer under the head of the bolt will sometimes keep it from spinning as you tighten it.