The most recent issue is now I need to make two support brackets. One for the A/C bracket and one for the alternator bracket. The headers wont allow the stock brackets to fit. I am gonna go to Home Depot and look for a 3" long piece of flat steel. I went to Copper State and bought long studs and 4 nuts to attach the bracket. I had a bolt break off in a head and won't make that mistake again. I tossed that 10lb frisbee in the junk pile Sunday. All I need now is to finish getting this back together and then tow it to Apache Muffler in Mesa for an exhaust system. Any recommendations on cats and mufflers ? I don't want it to be SO LOUD I can't think. I bought 2 tires for the front off a C5 owner. Less than 6 months old. Good score for $130. 245 45 17. Until I can afford a new set later this summer. I removed the seats last Sunday and put new foam and sheep skin seat covers int he plastic shells. I must say after 25 years it was about time a vacuum hit that area. I found a few odds and ends previous owners had lost. Thank God no old condoms. Mostly change ! The brackets are the reason for the post. I have seen a few pics so I have a good idea what this is gonna take to make work. Any advice ?

 

The stock A/c brace can be reinstalled by using a stock exh manifold bolt and cutting a tube spacer to
duplicate the length of the standoff on the stock manifolds

 

I cut my existing braces, threaded them, and used a thread sleeve to adjust for new length. The braces are bendable in a vice.

For new mounting points, I did this....
http://forums.corvetteforum.com/c4-t...h-headers.html


This picture shows my alternator brace (which is sprayed with duplicolor "CHROME" paint.


This picture shows the A/C brace -- though it's harder to make out.

 

Not to drag this off topic, but does the bolt on intake extension actually do anything?

 

If you are talking about the plenum distributor cover, that's all it does....hide the distributor. It's a factory piece...though some people remove it.

 

Thanks! I saw it while I was just surfing for parts and couldnt figure out quite what it did. I'll hold off on getting it then, I don't need my engine bay to look pretty just yet.

 

I used 2" wide flat steel on the air pump from the rear to the top of the intake...bent the ends to fit the mounts each end, even cut out a notch to clear something. 1/8" thick steel...never had a problem. Same type on the bvack of the alt. Flat steel run to the manifold bolts. Be SURE to use a longer bolt to mount the support...the old bolt will probably go in and start 2 or 3 turns but it will strip real easy in the soft alum heads...so just get a bolt thats longer to get as many threads as possible.

I made a tube steel brace for the a/c side similar to the original.

This flat steel brace has worked very well. Absolutely no movement in the accessories when the eng revs. The stock system allows things to move around, which resulted in a couple cracked accessory brackets in my case...the new PS bracket is available...the a/c copmpressor bracket is harder to find used. I even had to reinstall the air pump bracket with the top section cracked because I could not locate a new one right away...and the steel supports have held everything firmly in place. No sign of a problem..even with the cracked pump bracket.
The hardware store sells the flat plate in aluminum as well...and it would probably work ok. Only problem is that its not going to be able to be heated and bent or twisted to fit...so thats why I used steel.

 

I was removing the locking Summit bolt and it got stuck. Its half way out just looking at me saying Now What ! Have been applying polymer lubricant hoping for the best. A little each day. Removed the wheel well cover and A/C hoses hours of extra work. I just want to turn the key. Anyway might use a threaded hex cap with a stud attached to use for the A/C bracket and call it a day. Main concern is the damn header leaking. I will try to get it out. If it breaks then drill through it and tap it 3/8ths forcing the steel into the aluminum head. The major issue is the header is on the head as its in the CAR !! Gotta love it.