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So yea, another issue lol. I put Kooks 1 7/8's headers and cooks catless X on over the weekend. The headers themselves fit perfect. The problem is in the X-pipe. The portion that mates to the headers isn't tolerance correctly. Meaning, each pipe is a little off from the headers, so when I bolt everything together, it pulls the passenger side header in contact with what looks like a brake line or something of that nature that runs along that side of the car. Yes, I installed the header, X-pipe, and Mid-pipe loosely before tightening down. The X needs to be flared more for me to keep from pulling the passenger side header into this hard line. I have the car dropped off at MTI Racing Atlanta for a tune tomorrow. I am probably just going to pay them to fix this issue unless you guys can suggest an easy solution. Also, I am having a slight rattling issue as well because this misalignment brings the passenger side header close to the heat sheilding on the chassis where the header mates with the X-pipe. I will put some pics up tonight so you guys can see what I am talking about. I am not newby to cars, I don't see how it can fit rattle free without cutting the X-pipe, separating the 2 halves, and welding in a spacer.
Kooks fitment. That was my issue too. My headers fit beautifully to the block, BUT the cats to the midpipe was a real PIA. I had to go to Autozone and rent an expander to even have a chance to connect these pipes. I had no such problem when I connected my Corsa xpipe to the Corsa over the axle. Perfect fit with Corsa, no problem. I also tugged and pulled a long time under the car to get everything close with the Kooks midpipe, and when I was done I would say it was not satisfactory fit. But, I do love the sound, performance, and the cherry red high temp coating.
Now you guys have me worried? I am about to place my order, but have read several posts complaining about the quality and fitment issues, welding issues with the merge collectors, etc...
PS: Contact George R at Kooks, and have him send you a new pipe, instead of attempting to fix one that does not fit correctly.