How about simply exchanging them for a set that fit correctly?

If I understand you correctly, universeman, the hose clamps are serving as a collar holding the springy flanges up @2''. With the hose clamps tacked on they are unlikely to move even after the exhaust heat melts the NyLoc nut thingies. Kid Turbo did ask about spot welding the heater box to the exhaust pipes, but with the Heat Exchangers being made of dissimilar stainless steels with different Coefficient of Expansion for the heater box vs. the head pipes, it was decided to stay with the clamps. I didn't want to add more stresses and strains to things I know very little about. Nifty collars would look more Porschish, but when this idea popped into my head I grabbed the ball and ran. It's fast. It's easy. It's inexpensive. It's done. Well,,,almost. Couple more fine tweeks and we're there. Sawing off the extra clamp threads to gain a little more clearance. I had to rotate them so the nuts on the HEs can be reached and tightened. No,universeman. I didn't thing about the 3 stud part. There's probably 10 ways to do this, but talking it over with Glenn at PP about my radical hose clamp design sounded like a real doer.

'Cheers' Jip

RarlyL8. 'Rarely Late? My bike has a L8DGA2 license plate.
I may have failed to mention Aleisha, Bruce Stone and Glenn all jumped in on this. A fresh set was sent to me while the others were returned. And guess what. The right side HE was exactly like the first one. 1 1/2'' high at the flanges. Not 2'' like the left side. I thought about plain steel HE's hoping they both might fit perfectly. Then I remembered SSIs gain a little horse power and that is what I need. More horsepower. Please remember. The original 2.0 liter and trans are being removed and pickled and a supposedly OK running '79 3.0 installed with the older Heat Exchangers to keep the original heating system. Believe me. Looking at this new fangled 3 liter with its' miles of hoses, wires, boxes and mystery DooDads, plus some kind of electric fan mounted on the engine to blow heat is just too weird. I'm used to working on a cute little engine with a distributor and some carburetors. This 3.0 monstrosity is pretty intimidating to this old school hayseed.

'Cheers' Jip

Yes Rarely Late. Had that on my first 911 license plate and it stuck.

CIS is an ugly beast to be sure.
Unfortunately SSI is no more, they died when John sold the business/name to Dansk. John had one product and it was perfect every time. Price went up 30% and the quality went down. A true shame.

'Attention universeman'

I believe there are expansion/contraction issues regarding the dissimilar stainless steelses making up the shell and tubing.

Back again. Had to do a ditty in Mazatlan. Plus a couple of weeks getting the juices flowing. Upside down engine. Removed the oil pump screen from the crankcase drain. Cleaned. It didn't need cleaning. Re-installed. I didn't know it took two gaskets, so one new gasket was ordered and one used gasket was re-used. Engine looks sparkling clean inside. No visible signs of wear, that I can see. Cam chains are snug. Sprockets look good. In my opinion. I've never seen new sprockets.


https://jip-judy.smugmug.com/911/911..._0001_3-XL.jpg


Ran taps'n dies in and out of every hole.


https://jip-judy.smugmug.com/911/911..._0002_3-XL.jpg


Big decision time. The final countdown.


https://jip-judy.smugmug.com/911/911...MG_0003-XL.jpg

Almost there.


https://jip-judy.smugmug.com/911/911..._0004_3-XL.jpg

So now the Exhaust Heat Exchangers rest squarely in place leaving about 1/4'' clearance in the important spots. I've had the HE on the left side on and off a dozen times,,,just because.


https://jip-judy.smugmug.com/911/911...MG_0004-XL.jpg

Just most of the tools required to remove and install a Heat Exchanger. I forget which one(s) I left out.


https://jip-judy.smugmug.com/911/911...MG_0005-XL.jpg


Uh-Oh. Lower Rocker-Cover hits ducting on Heat-Exchanger Or Vice Versa.

https://jip-judy.smugmug.com/911/911..._0001_5-XL.jpg

A bit of final grinding and the rocker cover fits right on.

https://jip-judy.smugmug.com/911/911...MG_0007-XL.jpg

OK, now we're gettin' goin'. Slowly moving into the back together stage.

https://jip-judy.smugmug.com/911/911...MG_0001-XL.jpg

John Walker had it right. The mass-produced SSI build specs by Dansk are not as tight compared to the original SSI versions. Metal doesn't/shouldn't "move" that much to create interference unless they weren't built correctly in the first place.

Suggest you trial-fit the muffler to confirm the HE-to-muffler flanges are on the same wave length. Easier to revise at this time.

Sherwood

Good call, Sherwood. I was kind of moving in that direct. In my box of parts, PP sent 4 copper lock nuts for bolting on the muffler to the Heat Exchanger. That will be much later, during the engine swap.
There must be a lot of people out there in the world beating dents in their pipes.

Jip

Ok, back again. Really back, this time. So now is the time for the easy one. The other Heat Exchanger that just drops right on. I've had it on and off a dozen times during the slight re-design of the left hand HE on the upside down engine.
So, set the good HE on the engine, again. Everything has always lined up. Drops on. Lifts off. Height is right. Clearance is right. Gaskets in place. Three Socket Head nuts in place. Three 13mm nuts in place. Starting at the front snug down on the 2 nuts. Next one is the center exhaust. Snug down on the nuts. Third exhaust. Snug down on the 2 nuts. Then go back to the front to tighten a little more. Uh oh. I can no longer get the 8mm Allen Socket into the 8mm Allen nut holding down the exhaust flange. The HE had shifted enough to block insertion of the tool into the socket nut. Gee. Center hole is the same way. Can't get the tool down the hole and into the socket nut. After a few attempts to figure out a pattern to torque things down, all was lost. With loosening all the nuts it was decided to place three 8mm Allen sockets on three different 3/8th drive extensions. Because I didn't happen to have three 8mm Allen sockets the need to fabricate one was in order. Out come the Allen wrenches. Three 8mm's. One beater is the sacrificial wrench. Out come the die-grinder with a saw blade to cut the Allen wrench in two. Then the now 4'' X 8mm Allen Extension Tool(#911-23456) was inserted into an 8mm X 1/4'' drive socket and ratchet the 4'' extension and dropped into the hole in the HE. Now the are three 8mm Allen(Hex?) sockets in the 8mm nuts on the inboard side of the HE. Then I placed all three 13mm nuts on the aboard exhaust flange studs.Then, starting in the center I snugged down on all 3 socket nuts. Looking under the heater box of the exhaust I carefully withdrew and re-inserted and re-withdrew and inserted the 8mm socket into the socket nut, making sure I could get the damn thing back in once I torqued down on the rest of the 8mm and 13mm nuts. With loosening and re-tightening and re-lossening and tightening and throwing in a little shifting around of things I could finally get all three 8mm socket tools on all 3 sockets nuts and could withdraw and re-insert them into the socket nuts. This only took 2 days, but what the Hey, it's a 911. Then I could tighten all of the nuts, finally installing the Heat Exchangers once and for all.
In the photo are all of the tools to installed the HE's. The 3 extensions at once was the key in this episode.

https://jip-judy.smugmug.com/911/911..._0001_5-XL.jpg

https://jip-judy.smugmug.com/911/911..._0003_3-XL.jpg

Now, right side up and off we go on the other side.

https://jip-judy.smugmug.com/911/911...MG_0012-XL.jpg

Jip

Has SSI-Dansk improved its quality since 2016, or do the dimensional problems continue?