I ordered a set of the Dynatech Supermaxx headers and system from Tbyrne. Read the installation instructions on Dynatech's website and it seems pretty straight forward and simple but you know 'the best laid plans of mice and men'.
Has anyone done this install and run into unforeseen problems that I should know about before I start?
Any help will be highly appreciated.

 

Be careful not to damage your O2 sensors and keep them clear of the exhaust pipes. Probably doesnt need saying but do the same for the spark plug wires. You also may want to change out your plugs while you are in there and if you dont make sure you dont accidently crack one of the plugs.

 

Dick,
I did the install myself. I used the info from the install instructions that came with the headers, the instructions on www.ls1howto.com and from some of the forum members notes on the forum. It went quite well actually, but the fact that I have a lift in my garage might have helped. I have started the car up and left it running for 30 minutes three or four times occasionally revving the engine up to 4K - 5K. No problems with any codes. I would recommend the following:

After removing the two bolts from the starter to provide room for the header install, make sure that you tighten and re-torque the bolts before you even hand tighten the header on the passenger side. There isn't room to get to one of the bolts later without using a flex socket.

I removed the alternator completely to prevent it from falling down accidentally and damaging something.

I removed the coolant temperature sensor to allow more room but mainly to prevent it from being broken during the header install on the drivers side.
I did remove the ground strap but forgot to remove the oil temperature sensor wire from the top of the oil filter. As a result, working alone while pushing the header up from the bottom I pulled the wires out and had to buy a new oil temp sensor clip with pig tail and install it. It cost me $30 for that.

One last thing, you will want to put hi-temp anti-seize compound on the threads of the O2 sensors before you re-install them into the headers. I did not put anything on my spark plugs although some have said you should.

The pre-cat O2 sensors don't have a lot of room but do fit. Hopefully I wont have any problems from heavy engine torque or suspension compression.
If necessary, I could drill a hole in the tunnel plate above the sensors, but as for now will wait to see if there is a problem first. The post-cat sensors are on the mid pipes that can be rotated to where you want so there is no problem there. I had no real problem with the sensor wires but there sure isn't any length to spare. I have routed them and tied them up and don't think I will have any problems. Again, I won't really know until I drive the car for a while. This wont occur until winter is over, and I take my car out in the spring.

I found the install rather enjoyable but then I took my time. The only time I got into trouble was as I stated above and put the driver side header up in place without remembering to disconnect the oil temp sensor wire. Not only did I save the $300 - $400 dollars that the install would have cost me but I think that I did a better job than anyone else would have. I know that there are no stripped bolts or something left undone. Also, if and when the headers need re-torqueing, I can do it myself and not have to pay another $50 - $100 to have that done.

Hope this helps. If I can help you in any other way, please let me know.
Good Luck and enjoy!!

 

Yeah, I just ordered them as part of the same group purchase. I expect to see them by Tuesday. I will let you know how it goes. When do you expect to get yours?

 

That's some good information. Did you notice a big increase in power? What is the sound like?

 

I installed QTP's, but for the O2 sensors you need O2 sensor safe anti-seize to re-install. Autozone has it, make sure to read the back. Also, on the coolant sensor, rather than remove it, I put a socket over it while I installed my driver's side header. Either way, just take some precaution as it is easy to break. I also left in my plugs until the stock manifolds were out to prevent any rust particles or dirt from going in the plug holes. Good time to change plugs too.

 

More good advice. Much appreciated.

 

Take your time in routing the O2 sensor wires. If you burn them on the headers you will have problems.

 

Thanks for all of the good advice, I hate surprises.

 

Dick, here is a link to pictures of my completed install. Of course I spent a little time with the polishing cloth. I love the look!