Kooks ball flange bent
Thread Starter
Drifting
Joined: Apr 2009
Posts: 1,898
Likes: 9
From: Morrisville PA
Kooks ball flange bent
So the first time I installed my headers, I torqued the headers down before tightening the ball flange connector from the mid to the header. The result was that it wouldn't line up 100% true, and I ended up bending the two bolt flange on the header side. I am thinking this may be causing issues and leaking. Does anyone have any ideas how I can bend it back? It is a pretty damn thick piece of metal. If it was possible to remove it, I could easily stretch it back just by flipping it around and tightening the bolts against it, but its on the header side so you can't get it off 
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Burning Brakes
Joined: Jun 2010
Posts: 812
Likes: 2
From: Metairie Louisiana
Once the metal gets bent and then re-bent it begins to lose it's strength. I don't know how to recommend straightening it but I think the alignment issue you mentioned is the biggest problem.
Thread Starter
Drifting
Joined: Apr 2009
Posts: 1,898
Likes: 9
From: Morrisville PA
I only noticed the smell the last couple of days. Before that, I was smell free basically. So maybe something just got loose. I will get it up in the air tomorrow and just retighten everything.
Thread Starter
Drifting
Joined: Apr 2009
Posts: 1,898
Likes: 9
From: Morrisville PA
Didn't bother trying to bend it back, it was still doing its job just fine..pulling the ball inside the socket.
Anyway, I found my problem...it was leaking at the ball-socket joint. I checked both sides and all the bolts were loose, but not because the nut came loose...it was because the nut was bottoming out and they still weren't snugged together enough. So as I drove the car, the exhaust must have reset its position and the result was a loose connection. My solution was to just buy bolts with the same thread length, but a shorter non threaded side. I then stacked some washers on the non threaded side to shorted it up even more. I added a lock nut and lock washer to the other side and problem solved. I tightened down on it pretty good and I still had threads left to go...so I will probably get under there after it cools down and give it another tighten. I noticed the smell ONLY at long stop lights and drive thrus now. Thats great news. The car also has zero tick now and the exhaust got extremely quiet.
PS, took it out for a spirited run...90 degree heat SUCKS!
Anyway, I found my problem...it was leaking at the ball-socket joint. I checked both sides and all the bolts were loose, but not because the nut came loose...it was because the nut was bottoming out and they still weren't snugged together enough. So as I drove the car, the exhaust must have reset its position and the result was a loose connection. My solution was to just buy bolts with the same thread length, but a shorter non threaded side. I then stacked some washers on the non threaded side to shorted it up even more. I added a lock nut and lock washer to the other side and problem solved. I tightened down on it pretty good and I still had threads left to go...so I will probably get under there after it cools down and give it another tighten. I noticed the smell ONLY at long stop lights and drive thrus now. Thats great news. The car also has zero tick now and the exhaust got extremely quiet.
PS, took it out for a spirited run...90 degree heat SUCKS!
Last edited by mchicia1; Jul 16, 2011 at 02:47 PM.
