Dansk 45mm Headers Problems-issues
 

I have recently bought a set of Danksk 45mm Headers for my sons 1983 SC, its running an SC cased motor and the headers are advertised simply as 45mm OD headers Porsche 911

In fitting the headers I've run up with some serious issues, firstly the right side ( (when viewed from the back) sits up against the oil S hose running from the rear side tank to the oil cooler, in fact the header squeezes the rubber hose right where it joins the oil cooler, as soon as it runs it melts the hose. The other major issue, is that the left side pipe hampers the clutch actuator and spring, to the point that the clutch simply can't operate, that may work though on the earlier cars that didn't have the helper spring but I'm not sure.
The S oil hose problem is cured by using spacers to lower the headers, these are available from SPD costing $50 each, it doesn't help the clutch though

Hope this gives you a heads up in case you want to fit these

http://forums.pelicanparts.com/uploa...1557597025.jpg
Oil inlet, the hose squeezes on the header

http://forums.pelicanparts.com/uploa...1557597025.jpg

Pipes run extremely close to the drive shafts although these are under droop

http://forums.pelicanparts.com/uploa...1557597172.jpg
Here you can see how the pipe stops the clutch operation

a few things come to mind-

have you spoke with the vendor about returning them due to the circumstance you've encountered? might be good information for them to specify in the future.

if the vendor will not take them back, and I know it's not want you want to do with a new set of headers but.... can you take a ballpeen hammer and recess the pipes some for any relief? if it's real close at the clutch linkage maybe just a bit of reshaping would work w/o much loss in performance.


at the oil cooler S hose could you have a fitting brazed onto the outlet sending it up say 20 to 30 degrees to get the rubber hose to clear? that in addition to some of that exhaust wrap material to insulate it could be an option.

I hope the vendor makes things right by taking them back so my suggestions become moot.

Kind of like B&B headers where you can't get the lower covers off.

is it just the turbo covers or the standard ones too that can't be removed?

Not that it's that much help I can send you stainless flanges for 10 dollars each. There the same ones I use when making our headers.. http://forums.pelicanparts.com/uploa...1557606593.jpg

Ben what are your headers called?

Mine are for 914-6

www.914-6werkshop.com

Seems the ones with B&Bs all had turbo style covers. But it's the top edge of where the nut and washer seat that hits the pipe, so I would assume the standard ones hit also. Ass u me.

What's the exact model of those Dansk headers? Are they Dansk 91.022S?

Dansk seems to have an interesting range of exhausts but I have yet to find a clear guide about which of their products are suitable to which 911 models...

I'm going to guess those 45mm headers were designed to fit 964 or 993 engines. That might explain the interference with the clutch spring and oil cooler as those items don't exist on the 3.6L engines. If so these headers may fit on the 3.6L Varioram engine you have. Worth a try.

The Dansk Part number is 99 3198 011

I think we have a winner!

im not sure by any means, but that makes a ton of sense. the 3.6 would seem to benefit from the larger header tube size more than a 915 equipped example.


if that is in fact the case the vendor would be less likely to take them back IME. at least you know there could be a market to sell them if you stuck with em.


toomany, I visited your house above the golf course like 15 years ago to buy some used parts so im aware you were at onetime in the 925. where is your son's SC registered that smog testing is not an issue with the headers?

It looks ver similar to this one (link) which has an interesting note at the end:

Just in case it's useful for someone: the OP's headers were indeed Dansk 91.022S, I ended up buying them and encountering exactly the same clearance issues on a Euro '80 SC. http://forums.pelicanparts.com/support/smileys/wat5.gif