AO

Well, it's done. I got my Devek Level 2 Headers installed. Not easy, but it's done.

Just in case anyone wants to do this job in the future and needs a few tips, here they are.

The passenger side is pretty simple. I only needed to remove the brace betwee the cross member and the upper control arm. With that out of the way, everyhting is pretty straight fwd.

So yesterday I suspended the engine by some 4x4's and some chain (See oil pan gasket thread for details on this) with the intention that I would drop the cross member to gain better access to doing the driver side.

Well, after studying things, I decided not to drop the cross member and instead with the added 1/2" clearance I gained from lifting the engine, I removed the the oil filter, the heat shield that protects the motor mount, and the heat shield on the stock manifold. With a little wiggling the stock manifold was out.

Now, ont he Devek Level 2 headers, the driver side comes with a slip fit connection for cylinder #8. I thoguht I knew how this stuff went together, so after much grunting, I got the larger section (cyl 5-7) bolted up. Then I went to put cyl #8 on and of course it won't slip on when the other section is bolted up.

Oh, and cyl #6 is a total bitch to get at. Had to cut down a wrench to get at the nut...

So after I took all the nuts off again, I got cyl #8 on got everything aligned. But now there is litterally no room to get your hand in there to get the nuts started on the studs. So I must have tried for over 30 min just to get on nut on using the socket to get it started becasue the damn washers kept falling off.

Finally at about 2:30AM I called it quits with 2 nuts left to go.

Got up this morning and after a nice bit of breakfast with the kids, I got back at it and finished up the final 2 nuts, modified the heat shield so it would fit again, and cleaned things up a bit.

Anyway... they're on. And I ain't ever taking them off (unless I really have to).

Now, I need to figure out what i want to do for the rest of the exhausts, but that's the easy part compared to bolting these things up.

pics...

Before...




Passenger side done.




Driver side done!








Found the leak on my oil cooler!



Next up... the rest of the exhaust!

pjg

Do you need to take the headers off to replace the clutch ?

AO

Doesn't look like it. I can certainly get at all 6 bolts for the LBH cover, but whether I can get the clutch down is another question, but it looks like I can.

pjg

I have the MSDS headers and they seem to have less room to access the clutch than the Devek style, is there any give if wanted to spread them apart a little ?

hacker-pschorr

Nice work!!!! Yes, changing out exhaust manifolds of any kind on a 928 is a royal PIA. I would rather swap out a clutch master (the right way).

Check your e-mail

The only suggestion I should have made earlier is what I'm going to my headers. I've having Todd cut off the three bold flange and weld on a V-Band clamp. Much better seal and easier to remove / install if needed.

I would recommend anyone with MSDS headers do this or at least weld on a 2nd 3-bolt flange. The flange from MSDS is really thin and will warp / leak eventually.

AO

No give. My friend has an '82 5-speed with MSDS headers and everytime he has to loosen up the headers to get at the clutch. PITA!

Richard S

Good job on the install, isn't it funny how one or two simple nuts/bolts can refuse to cooperate, yet fall right into place the next morning after sleeping on it.

I hate to say this, but I'm going to remove my Devek L2 headers. California have taken all the fun out of performance mods that can be seen during the visual portion of the smog inspection. They must really be pushing/training the smog shops to spot this kind of thing...getting harder and harder to find a shop that doesn't know what they are looking at, even on 928's.

Rich

Jon B.

^^^ I have someone interested if you really want to get rid of them. AO, were all the flanges just a two-bolt?

Silver79

PM sent Richard. Joe

JWise

Richard - check your PM.

Short of a full Greg Brown header/exhaust masterpiece, I figure a less expensive route would be a set of Devek L2 headers feeding into a Motorsport SLC X-pipe and 2.5" cat-back exhaust.

I have a X waiting to be installed at Sean's and the 2.5" cat-back is readily available, the only difficult piece of the puzzle is the Devek L2.

Emissions inspection? I ain't got no stinkin' emissions testing (or vehicle inspection for that matter) here in the Great State of Oklahoma.

AO

Yep, but multi-drilled to fit either 16v or 32v.

AO

Yep... you'll need to fab your own x-pipe.

Jon B.

Very cool, thanks for the clarification. I had thought I read that when they were still available, but I wasn't completely certain.

123quattro

Let me know if you want me to fab up the SS parts to connect those to the rest of your exhaust.

Ducman82

looking good!