Headers on ZZ4 D-port heads

[my79monza]

does anyone know if there would be any issues sealing my Hooker 2135 headers to the D-Port heads on my ZZ4?
read somewhere that D-ports had sealing issues and required different headers.
Merle

[Roccosvega]

You are correct, The flange for those heads is completely different.

Robert

[rocketride]

Merle,

I wonder if you could weld some d-port flanges to the headers and make them work?

http://www.jegs.com/i/JEGS/555/31802/10002/-1

Jon

[cjbiagi]

Merle, I know you bought a set of used 2135's, I don't see why you can't cut of the flanges and weld on the D flange as mentioned. It's also helpful the flanges on the 2135's are cut because you have the slip fit design. It would take a good welder and you may have to modify the ends of the pipes where they fit into the flange but it should be do-able. I would check out a couple local mufflers shops and talk to them and see what they say. Of course the trick is to make sure you get them positioned correctly to mate up with the head before fully welding them.

[my79monza]

Well they say it can't get any worse, it just did.
I have a new in the box set of Ceramic coated Sanderson headers that I have had for a few months and never really looked at them cause I thought all was well.
WRONG!!!! The damn things have large oval ports, NOT the D-port flange.
Now I have two sets of headers that are basically worthless for my ZZ4.
I was going to try both set of headers and the set that fit the best I keep, the other was to be sold, now ?????????????????
I could just freaking SCREEEEEAAAAAAAAMMMM.
Merle

[Roccosvega]

Merl, You should buy the flanges and have your 2135 headers converted they would be perfect.

Robert

[my79monza]

Well, I made a cardboard pattern of the port from my Hooker 2135 and checked it to the head on my ZZ4.
The bottom of the 2135 port is 1/4 lower than the ZZ4 port the rest is an exact match.
I am thinking about using a piece of metal shaped like a Woodruf key amd welding it into the bottom of each header port on the Hookers and then grind it flat to match the rest of the port, less work than trying to change the complete flange.
Merle

[Roccosvega]

You could weld stringer passes on top of each other then smooth with a dremel .Good to go.

Robert.

[cjbiagi]

If the port on the header is bigger than the head why would you have to do anything? It's not blocking anything right? Sounds like it should still seal too?

[my79monza]

Header port is larger than head port on bottom by 1/4" machined surface is 1/2" all around exhaust port, so if one does nothing to the header it still has the 1/4" of sealing surface.
should be enough?

Merle

[cjbiagi]

I would think that's ok, just make sure you get a real good quality gasket. Some good locking bolts will help to. I use Stage 8 on mine.

[my79monza]

Who makes the best header gaskets?
and where does one find the stage 8 locking bolts?
Merle

[cjbiagi]

There are some that are steel core laminate, others are copper embossed. I use the steel laminate and have not had a problem. If you need these or the locks let me know, I think you know how to reach me