SSI Install went great with help from all

[VFR750]

I want to say thanks to everyone on the BBS for helping me install a set of SSI's on my SC. Through the use of the search function I was able to find posts on just about everything I needed. I can't identify everyone who helped, however, when you see my lessons learned, you'll know how you helped.

Things I have learned through this experience:

1) It was less difficult than I thought to take the old exhaust off and install a used set of SSI.

2) That is NOT to say it was easy. I thought it was going to be REALLY bad. Patience, time, and thinking about what you are doing, before you commit to it, is the key.

3) A broken head stud is not a big deal. See below for how I dealt with it.

4) The funky wrenches for getting to the Heat Exchanger (HEX) nuts are worth it.

5) McMaster Carr sells 1/8" diameter carbide burrs for only $5.50 ea.

6) A MAPP torch & PB Blaster can only do so much against 26 years of rust. Do try to take the nuts off when they are hot. But be pragmatic. At some point, it is better to cut a slot deep into the nut and use a drift to turn the nut. If you are careful, you won't damage the studs.

7) If you are careful, you can cut the nut off the oil line to the thermostat without damaging the threads on the t/stat.

8) For a SC, you need both, the under-engine oil line, and the line to the thermostat.

9) Get a 36mm box wrench, and make you own oil pipe wrench by cutting a slot so you can get the wrench past the oil line itself and onto the inner oil line nut. You don't have to remove the outer oil line at the T/stat to be able to get this custom wrench onto the inner nut.

10) Make custom tools as you need them. Tools are cheap, and the right one make all the difference. I cut and bent a few wrenches to get just the right angle and clearance in those tough to reach places. I also borrowed some from Tom Butler (Thanks)

11) Aircraft Spruce sells 2.5" diameter silicon coated fiberglass tube, that works perfectly between the SSI heat exchanger inlet and the LHS tube that is integral to the SC's rear engine tin. $11 for 2'. You only need 1'. You don't have to backdate the engine tin.

12) The O2 sensor lead is too short when mounted in the SSI port. You have to make it longer.

13) Don't forget the anti-seize on the threads.


In the spirit of the forum, I'll share my most important learning: Do not fear the broken head stud. Do buy a 1/8" carbide burr for you Dremel tool, and a set of cobalt drill bits. Get a really good pair of goggles to keep the razor sharp metal chips out of your eyes. Don't ask me about how I know this....

I was lucky. Only one stud broke. Twice. First time was when the stud snapped flush with the HEX flange. The second time, when the stud removal tool snapped it flush with the head. Yes, I tried heat, PB, repeat, etc....

To get the stud out I center punched it, Drilled into it with a 1/16", 1/8", 3/32" and a 5/32" cobalt drills, taking my time, with oil for cooling. Then I used the carbide burr to slowly carve out the stud from the inside out.

When I could see the impression of the threads in the surface I was grinding, I knew I was close. As it turned out, I was able to pull the steel threads out of the hole, like a heli-coil. Unfortunately, I did not carve the full depth of the stud as I should have, and had to regrind, and then use a tap to get the rest. The new stud was a little loose, so I used blue locktite to hold it. (Yes it will likely be a bear to get out next time)

One stud took two hours. On my back. Looking up. With a down jacket, laying on wool blankets on the floor, full coverage safety goggles and gloves. It was ~25F. I could see my breath. Don't you just love New England winters?


So I am almost done. I need a replacement band clamp for the HEX ducting. Took about one month working every now and then. Can't wait to fire the car up, and go for that first drive.

[snbush67]

I nominate that you recieve 53.7 pelican points for this post. I voted excellent.

[Gogar]

Yeah, congrats! That's a great post.

You mean "Exhaust stud", right?

[oregonmon]

You got some cojones.

[Jadams1]

Should have waited, it will be in the 40's this weekend (New England Heat Wave). When I installed mine and started it up the first time, it definately put a smile on my face. I went with a used dansk 2 in 1 out SS muffler. I bought all my stuff used too.



Here's a New England weather forecast cartoon for you. Congratulations!

[VFR750]

Originally Posted by Gogar

Yeah, congrats! That's a great post.

You mean "Exhaust stud", right?

Yes. "exhaust stud". I have not had the "pleasure" of dealing with the long head studs.

My guess is, you could do the exact same thing, carve it out. Especially if it looks like your "headed" for disaster.

[DTW_JWA]

Can anyone help me to locate a good used set of SSI?

[ninesixfour]

Nice work. Where'd you find a used set of SSIs?

[VFR750]

I got my used SSI from tom1394racing. You might contact him, he had another set when I bought mine.

[Paulporsche]

I have the same setup on my car, w/o the O2. I think you'll like it. Let us know.