Short Kleeman headers
These Kleeman headers I bought on eBay ….. don’t really know where they came from but they should fit on my car. As this stainless steel is stiff and no place is there plenty of, then it is most important that the fitment is correct. It means that I will have to cut my existing exhaust and weld a new flange on it which will connect with the Kleeman headers. It is vital you make a 100% fitment since it stiff and no place for errors – a flange that do not fit 100% will only give you headaches and grief.
I had a template made for a new flange – first off finding the correct gasket – as it turned out after been in contact with Kleeman it’s a gasket from Audi ! Then I had an Autocad drawing made and then ordered some new flange. At the same time I had an Autocad drawing mad for a flange that fits on the engine block. (it was when I had the idea of making my own headers – luckily I did not go down that road which would have meant a lot of extra work)
I had already made several new flanges that fitted the gasket which is from Audi. The Audi part number for the gasket is 8D0 253 115
After this I had the main templet for the flange adjusted so next time – or if anybody should want them – new flange that will be cut should fit even better. The holes for the bolts has also been adjusted so they will not be so close to the inner hole.
It was quite easy for me since I already had my engine out – I had it on a stand and made a big plate that I ensured was in 100% level. The degree the engine is placed in the car I did my best to manage on the stand.
Then I fixed the first stage of the exhaust on the wooden plate bolted on to the engine with the original headers. In this way I was sure the exhaust system lay in the right place.
As you also can see, then I deleted my 1. stage mufflers – to get the really good sound;) …. but that’s not what I will show you here.
One side at a time – first I had to cut the existing exhaust ….. took it carefully since it is all down the road of no return.
It soon appeared to me that I was not able to get the ends to meet whiteout the possibility of adjusting the angels on the catalyst – I still have to keep the catalyst due to the law in Sweden.
So I cut loos the catalyst by cutting the old weld very carefully – note that I did not cut the piping so the catalyst fell off – simply cut away the welding so it became loose. It is a pipe formed as a “trumpet” that is trapped inside the catalyst so when it is loos I can turn it in any direction.
Also quick appeared that I had to cut back the flange on the Kleeman headers – so the old flange went off.
Had to make 100% sure the fitment was OK before welding – therefor I had to put the engine in and the exhaust on. It was a success.
The flanges of the headers were not straight so I decided to have them machined. For that I needed to build a stand so they could be secured for this process.
