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I pulled my EG33 out of a perfectly good running SVX that I drove around with no smoking, overheating, or any other problems with the engine that only had 100k miles, so I am pretty sure the block and cylinder heads are fine (ie. not warped or misshaped).

So, my question is this. Is there something different about my motor that would cause both of these headers to not fit?? My SVX was one of the first, manufactured in early 1991. Is it different in any way? or did I just happen to get TWO headers that don't fit in the SAME fashion?

I am thinking about towing it down to an exhaust shop and having them try to put it on. All I have left to do before my first startup is finish up the wiring, install the charcoal canister and put the DAMN EXHAUST on! I am very frustrated right now! #$%* If anyone can help, I really need advice on this header issue.

Thanks,

Chris

Chris:
We had a similar experience with 3.3 headers. First set was way off. We exchanged that set for a second set which were also off but closer than the first set. It took a bit of wrangling but they were finally mated. It has been a couple of years and the van has been used sparingly but so far they have not cracked. Others have reported similar experiences with poor fit.
Craig

--- On Mon, 3/19/12, Robert Stevens <mtbiker62@...> wrote:

From: Robert Stevens <mtbiker62@...>
Subject: Re: [subaruvanagon] Small Car SVX Stainless Header won't fit.
To: subaruvanagon@...
Date: Monday, March 19, 2012, 11:44 PM
















??











On Mar 19, 2012, at 10:02 PM, Christopher wrote:

I pulled my EG33 out of a perfectly good running SVX that I drove around with no smoking, overheating, or any other problems with the engine that only had 100k miles, so I am pretty sure the block and cylinder heads are fine (ie. not warped or misshaped).

So, my question is this. Is there something different about my motor that would cause both of these headers to not fit?? My SVX was one of the first, manufactured in early 1991. Is it different in any way? or did I just happen to get TWO headers that don't fit in the SAME fashion?

I am thinking about towing it down to an exhaust shop and having them try to put it on. All I have left to do before my first startup is finish up the wiring, install the charcoal canister and put the DAMN EXHAUST on! I am very frustrated right now! #$%* If anyone can help, I really need advice on this header issue.

Thanks,

Chris

My suggestion is to get a refund from Small Car on the header that doesn't fit, that you've already paid for.

Then, as you have said, take your van to a shop that can make a complete header that the exhaust system

you have will bolt up to. Have them make it out of mild steel, then have that ceramic coated. Be sure to

know that there are fabricators that have been making headers out of a lot of materials, on the internet,

that can make a header for you.



I'd suggest avoiding stainless. The really good SS (I think it's called 321) is VERY expensive and not

a lot more durable than mild steel with the ceramic coating.



An example of one of the online vendors finished product:







I'd suggest talking with them about them or another vendor they recommend, making this same unit

out of mild steel if they can/will. My experience with SS headers on both Subaru 2.2 and 3.0 is that they eventually

crack in several places.



Just my $0.02



Bob



[Non-text portions of this message have been removed]



























[Non-text portions of this message have been removed]

Hi,
I had the very same problem about 3 years ago. As much as I tried I could
not get the on. I noticed that they were about 1 inch closer together on
the far end then from the crossover end so I put them on a vise and
carefully pulled until I got the desired length.
They were still hard to get on but I was able to do it. I think when they
were made they were not allowed to cool and may had actually warped.
The headers did not last very long and I have since had a shop do a customer
setup for me.

_____

From: subaruvanagon@... [mailto:subaruvanagon@...]
On Behalf Of Christopher
Sent: Monday, March 19, 2012 9:02 PM
To: subaruvanagon@...
Subject: [subaruvanagon] Small Car SVX Stainless Header won't fit.




So, I ordered pretty much all of my conversion parts from Small Car
Performance, including the stainless header. The header looks very nice and
shiny. The only problem is I can't seem to get it to fit. The bolt holes on
the header closest to the crossover pipe are too close together and no
matter how hard I torque on it I can't get it on. I called Small Car and
sent it back so they can repair or replace it. He calls me when he receives
it and claims he is able to get it on a spare SVX motor they had lying
around by himself!!! So, I figure "Hey I must be just a little wuss and need
to try harder!"

Ok, so he sends it back to me. Same deal, no good; I am trying everything,
put one side on then the other, front then back, even using my feet against
the transmission and pulling... NOTHING! I then stop, go inside and using a
ruler and camera, take meticulous measurements of the header bolt hole
spacing, a bunch of pics send an email back to Small Car, asking him if the
measurements I sent are withing specified parameters? He calls me back and
says "There was a bad batch, and checked another one he had on the shelf."
Then he says "I'll send you our display model. It has a dent but it should
fit." I tell him that is fine, as long as it fits, I don't care about the
dent. It gets here and I try for an hour and a half to get that thing on,
but the same thing happens, the bolt holes on the header on the forward side
(near the cross pipe) are too close!

The measurements of the exhaust header bolt holes center to center from Van
front to Van rear are:

21 7/8 inches
16 7/8 inches
22 inches
17 inches
22 1/4 inches

The rear bolt holes line up fine (22 1/4) it is the rear bolt holes that
seem to be too close together (21 7/8)

I pulled my EG33 out of a perfectly good running SVX that I drove around
with no smoking, overheating, or any other problems with the engine that
only had 100k miles, so I am pretty sure the block and cylinder heads are
fine (ie. not warped or misshaped).

So, my question is this. Is there something different about my motor that
would cause both of these headers to not fit?? My SVX was one of the first,
manufactured in early 1991. Is it different in any way? or did I just happen
to get TWO headers that don't fit in the SAME fashion?

I am thinking about towing it down to an exhaust shop and having them try to
put it on. All I have left to do before my first startup is finish up the
wiring, install the charcoal canister and put the DAMN EXHAUST on! I am very
frustrated right now! #$%* If anyone can help, I really need advice on this
header issue.

Thanks,

Chris

Yeah, I just tried again tonight. I finally got the exhaust header to
fit. Ended up using the engine hoist and a couple of straps to stretch
it out on the crossover side with the open end secured with the rod it
ships with. Then I was able to get the very tips of a couple of the
bolts through the holes, then used a mallet to bang the rest on. At
that point I had quit caring about damaging the threads of the bolts.
I got it banged on enough to get the nuts started. And finally after
much ado, SUCCESS!!!

So, thanks for the advice everyone. I am close to starting this beast!

I definitely believe they warped and misshaped after they were allowed
to cool.

--- In subaruvanagon@...
<mailto:subaruvanagon%40yahoogroups.com>, <wic@...> wrote:

Hi,
I had the very same problem about 3 years ago. As much as I tried I

could

not get the on. I noticed that they were about 1 inch closer together on
the far end then from the crossover end so I put them on a vise and
carefully pulled until I got the desired length.
They were still hard to get on but I was able to do it. I think when

they

were made they were not allowed to cool and may had actually warped.
The headers did not last very long and I have since had a shop do a

customer

setup for me.

_____

From: subaruvanagon@...

<mailto:subaruvanagon%40yahoogroups.com>
[mailto:subaruvanagon@...
<mailto:subaruvanagon%40yahoogroups.com>]

On Behalf Of Christopher
Sent: Monday, March 19, 2012 9:02 PM
To: subaruvanagon@...

<mailto:subaruvanagon%40yahoogroups.com>

Subject: [subaruvanagon] Small Car SVX Stainless Header won't fit.




So, I ordered pretty much all of my conversion parts from Small Car
Performance, including the stainless header. The header looks very

nice and

shiny. The only problem is I can't seem to get it to fit. The bolt

holes on

the header closest to the crossover pipe are too close together and no
matter how hard I torque on it I can't get it on. I called Small Car and
sent it back so they can repair or replace it. He calls me when he

receives

it and claims he is able to get it on a spare SVX motor they had lying
around by himself!!! So, I figure "Hey I must be just a little wuss

and need

to try harder!"

Ok, so he sends it back to me. Same deal, no good; I am trying

everything,

put one side on then the other, front then back, even using my feet

against

the transmission and pulling... NOTHING! I then stop, go inside and

using a

ruler and camera, take meticulous measurements of the header bolt hole
spacing, a bunch of pics send an email back to Small Car, asking him

if the

measurements I sent are withing specified parameters? He calls me

back and

says "There was a bad batch, and checked another one he had on the

shelf."

Then he says "I'll send you our display model. It has a dent but it

should

fit." I tell him that is fine, as long as it fits, I don't care

about the

dent. It gets here and I try for an hour and a half to get that

thing on,

but the same thing happens, the bolt holes on the header on the

forward side

(near the cross pipe) are too close!

The measurements of the exhaust header bolt holes center to center

from Van

front to Van rear are:

21 7/8 inches
16 7/8 inches
22 inches
17 inches
22 1/4 inches

The rear bolt holes line up fine (22 1/4) it is the rear bolt holes that
seem to be too close together (21 7/8)

I pulled my EG33 out of a perfectly good running SVX that I drove around
with no smoking, overheating, or any other problems with the engine that
only had 100k miles, so I am pretty sure the block and cylinder

heads are

fine (ie. not warped or misshaped).

So, my question is this. Is there something different about my motor

that

would cause both of these headers to not fit?? My SVX was one of the

first,

manufactured in early 1991. Is it different in any way? or did I

just happen

to get TWO headers that don't fit in the SAME fashion?

I am thinking about towing it down to an exhaust shop and having

them try to

put it on. All I have left to do before my first startup is finish

up the

wiring, install the charcoal canister and put the DAMN EXHAUST on! I

am very

frustrated right now! #$%* If anyone can help, I really need advice

on this

header issue.

Thanks,

Chris