I have a header question

Ok, so I ordered a set of headers for the 944 a few months ago and finally got around to trying to put them on this last weekend. I found that the mounting holes are off.

I contacted the guy that made them and he said I can send them back and have them re-made (new ones, or rework these?) or I could drill the holes larger. From the picture, all of the holes would have to be quite a bit larger. Seems the header could walk a bit with such over-sized holes? Another issue, if I drill them I'd break the ceramic coating. Isn't part of the benefit of ceramic coating corrosion resistance?
So, I think having him build me new ones is the way to go, but am I a big baby because I don't want to have to pay shipping again?
If any LSX/944 guys read this, can you shoot me a PM, I want to give you specifics that aren't in this post to get further feedback.

Dont drill the header. Drill the cylinder head and fill the old holes with melted wheel weights.

If the bolt holes are off that far will the exhaust port line up with the header tube? I'd get him to build a new set.

+1 for building a new set.

DeadSkunk wrote: If the bolt holes are off that far will the exhaust port line up with the header tube? I'd get him to build a new set.

This is my question. Odd that the flange would be that far off, unless he's hand-fabbing a new flange for each header? He's not checking his work against a known head?

i would say get a new set that fits the way its suppost to. if your really set on this one dont drill the hole in the header bigger, just elongate it to where the bolt can slide over enough to fit

edizzle89 wrote: i would say get a new set that fits the way its suppost to. if your really set on this one dont drill the hole in the header bigger, just elongate it to where the bolt can slide over enough to fit

I'd say new one too. not easy to hold a header in a milling machine to slot the hole and free hand will never come out straight then you have to think about sealing the header to the head...

Thanks guys. The more I think of it, I want a new header for the reasons stated. Now, am I being a baby/prick if I refuse to pay for shipping again? Should I ask if he'll split it with me?

Nope. Build it right or make it right.

DrBoost wrote: Thanks guys. The more I think of it, I want a new header for the reasons stated. Now, am I being a baby/prick if I refuse to pay for shipping again? Should I ask if he'll split it with me?

He should probably pay for return shipping both ways if he messed up and it was well understood what head it was going on. That's way off. He obviously never test fit it. I worry about the rest of the construction after seeing that.

tuna55 wrote: He should probably pay for return shipping both ways if he messed up and it was well understood what head it was going on.

I second that emotion.

I would've told you to just redrill the flange if not for the ceramic coating.

N Sperlo wrote:

tuna55 wrote: He should probably pay for return shipping both ways if he messed up and it was well understood what head it was going on.

I second that emotion.

This is for my specific swap. That's all he does is LSX/944 swap stuff. So yeah, he know. And I agree, if it wasn't for the coating, I'd just weld/fill and re-drill.

You can't just re redrill it. The port will be off as well.

Recast the cylinder head. That way you can move the ports and hole where ever you want.

logdog wrote: Recast the cylinder head. That way you can move the ports and hole where ever you want.

I'd like to recast your head. I'm sure I could do a better job.

Youre just jealous I thought of it first