Help! heat exchangers don't line up
 

Help!!
What do you recomend when the heat exchanger access holes don't line up close enough to install the barrell nuts. Their close but not close enough on several, and there is little or no wiggle room for thr special tool to compinsate. The ex's came off a different engine but are the correct ones(1971 2.2E). Any ideas??
They are in excellent condition and don't look damaged in any way.
Cosmo

Cosmo, you may have bent or crooked exhaust studs on your engine. I had a couple like this (just slightly) on the 73E and needed to expand the holes a little bit on the heat exchanger flanges for the SSI's I recently purchased. Fortunately, the ones that were crooked were not the ones that held the barrel nuts, nor were they very crooked. In your case, I'd verify whether or not the studs are straight and perpendicular, and if not, replace the offending studs.

I had the same problem with a few holes on the SSI's. The old heat exchangers lined up fine but the SSI's were a bit off. These were new. I got the barell nuts started with my fingers. I rounded off the edges of the bottom of the hex tool just a little so it would give it a little slop while first entering the hex hole in the barell nut. I could then lightly tap it in the rest of the way with Maxwell's hammer. (My little tiny ball peen.) It worked for me but it wasn't easy. I don't think my studs wer bent at all because they slid into the flanges like butter.
Good luck!