Finished my Kooks and Corsa Sports install over New Years. Just wanted to post what worked for me in case someone else can use some tips. Not intended to be a start to finish install post. Just some additional info.

After all the boxes arrived my initial concerns were unwarranted. See my prior post -

http://forums.corvetteforum.com/show....php?t=1885162


The quality, finish, labeling, packaging and fitment of all the components was 100%. I had no issues with the Kooks and Corsa parts fitting together and to the car.

I got the car 20 inches off the ground. It was more than high enough and always ample room. I always provide a backup in case of jackstand failure. Dead men don't drive Vettes with headers!




The original exhaust came down without a problem -
1. It wasn't necessary to move the rear sway bar or remove it's mounting bolts to remove the factory exhaust or install the new Corsas.

2. Spray the exhaust manifold to cat bolts with PB Blaster a couple hours or overnight prior to starting.

3. Some like to remove the manifold and cat as one piece. I found it easier to remove them as two separate pieces. I tried each bank each way. I was working by myself the parts were easier to handle after being unbolted as two parts. Having been sprayed with PB the night before getting the bolts loose wasn't a problem.

4. Spend the $12.00 and buy a 7/8" - 02 sensor socket. It's tight getting the forward ones out of the stock manifold without one. If you damage it they are not available at an auto parts store. Local Chevy dealer wanted $114.00 for one and had to order. Luckily, the one I put a small dent in the upper body of with a wrench turned out not to be damaged. Went next morning and bought the 02 socket for the other side. I like acquiring tools for future projects anyways.

5. I labeled all the old parts passenger and drivers side and stored away. My memory is excellent just not very long

Installing the new parts -
1.Take notice that one of the rear 02 wire extensions provided is longer than the other. The longer one goes on the drivers side. If you mix them up they won't be long enough to plug in. Yes, I got them mixed up the first time.

2. This is what I used to secure the wire extensions. They are left over from a recent remodeling at my house. Simply 1/2" metal conduit pipe clamps. The holes in then didn't have to be drilled for the tunnel plate bolts. Purchased at Lowe's. Also in picture is metal furnace stove pipe tape I had laying around.



This is the hole and clamp position that worked best to get the wires and electrical plugs the furthest away from the cats.



And just in case a strip of metal furnace tape securing the wire to the tunnel plate.



3. Gasket selection - I was seduced by the good looks of the much thicker (.062) Kooks gasket. DON"T DO IT!!! I had an immediate gasket leak the first time I started the car. I've spent more than a few years as machinist persuading metal to do what I want. It wasn't going to happen or work and gave up after a couple hours. Installed the used GM gasket and NO PROBLEM. Ignore forum members advice at your own peril. BTW a header leak on my car sounded like a bad lifter. Really surprised an exhaust leak could make such metallic clicking sound.

Conclusion -
Most everything has been covered by prior posts. These are just some tips maybe someone up in the air about doing their own install maybe able to use. My car isn't my daily driver so I took my time and enjoyed the install. It was easy and no way near the nightmare of header installs I've done on cars in the 1970's. As you can see from the snow in the background I'm locked into snow and winter for awhile. No way to road test my recent mods. All I can do is start it and go VROOM! VROOM!



And the Corsa Sports from the rear



Special Thanks -

Maryland Speed - great company, great staff, excellent attitude!

Brandon @ Maryland Speed - for calling me back on a Sat. to answer what was probably the stupidest question ever asked about installing headers.

George R @ Kooks - for adjusting mfg. process to address my concern, I'm honored!

All forum members who PM'd me with offers and members who took time to post prior information

My wife - For noticing my new Corsa's and saying they looked and sounded great without me even asking.

Miller Brewing Company - For keeping me hydrated after I was done wrenching.

 

Looks like my install last weekend. I also had jack stands and used a combination of 4 rhino ramps with 2 x 12 boards stacked under the tires. I, like you, felt more comfortable with eight supports. That vette was going nowhere with me under it. Two problem areas for me were two stubborn spark plug wires and one stubborn O2 sensor on the manifold. Took some soaking with liquid wrench to persuade it to come out. Other than that, also a special thanks to Branden at Maryland Speed and Jet Hot Coatings for great customer service and professionalism.

 

Love the Kook's, Plus they fit like a glove. Now add Z-06/npp mufflers
and a one button exhaust controller.

Am I seeing the cats only a half inch from the tunnel plate?

Mine had about with out going out to the garage,
about 1 1/4" clearence so I made a tunnel plate heat sheild out of some
sheet thin stainless, It has 5/16 clearance from the tunnel plate,and fastens at five points.then the cats are another 3/4 from it.

 

No, it's a parallax error from the camera angle. I have more than 1/2" clearance to the tunnel plate. No way could I lower the X pipe without road clearance being an issue.

Sorry, I can't follow the second paragraph of your post.

 

Glen, Enjoy the power and sound. It is a different car... now find yourself a tuner like Jeremy Formato and see what is possible now that your car can breath Sorry, I didn't pick up your question earlier.

 

Glen,

Awesome buddy, did mine the Saturday after Christmas on jackstands, race ramps and kept the jacks underneath for added security. Glad everything went well now enjoy the fruits of your labor, awesome performance and great sounds.

 

 

Ditto. Do get an O2 sensor socket, and re-use the OEM bi-metal gasket.

Great job