Kooks Catastrophe
When ordering headers from this "custom header" company they specifed that the engine needed to be in its factory location. Not a big deal. So we specified the year, make, model, 8.2 deck 302 based engine with AFR 205 heads, and manual trans. You would think that for the $$$$$ they charge for these things they would fit. Uh, NO. Not at all. We even went through the trouble of measuring the engine location of 6 other 1993 mustangs all of which were bone stock (Never modified in any way). Funny they were all within .125" of each other including ours! So after running them on the engine dyno prior to getting them coated as they suggested, and later finding out they did not fit, they basically told me that we were screwed. Yep thats right, we did what they said, and that made it to where the headers were now un-returnable for refund. Man, I love wasting money for uncoated stepped headers!
The first picture here is of the headers as they were installed as received from Kooks. Like the 2x4? Yeah, well they told me the car was "sitting too low and it will never 60' sitting like that". Ok, right and all the Pro50 cars and outlaw cars sit up like 4x4 trucks. I guess sub 1.2 sec 60' aren't considered good in their eyes.
In the second picture you can see how each tube was cut, modified and welded back together.
After cutting each tube in a relatively straight section, we positioned the collectors where they needed to be and began fitting and tacking the tubes back together. Each tube had to be cut and modified by either shortening, adding slight bends, or grinding compound angles to get them to fit properly. Once all of the tubes were tacked in place, a final check to be sure the collectors slipped on and off without binding once done. Here you can see that after several hours re-working / fixing of the headers, they fit great with plenty of ground clearance!
