Has anyone run across this?

[4steri]

I'm building a MKIII. The body has been fitted, the engine is in and level. The BBK header on the driver side does'nt match up with the cut out. The header is about 1 1/2 in high and about 1 in to the rear of the cut out. The driver side header is 5 degrees higher than the one on the Passenger side. I've sent pictures of the set up to FFR on 4/10 but haven't had a response as yet. I think the header is mis formed. What do you think? Any suggestions short of cutting the cut out?
Frank

[Jeff Kleiner]

Frank,
The Hooker 4 into 4 headers are notoriously ill fitting and inconsistent but the BBKs are much better. However in either case install the front splash panels before getting too worried about the fit. They will move the lower edge of the body outward and often that is all that is needed. Additionally, I've found that the FFR sidepipe cutouts are made small so that the builder can fine tune the fit and depending on the type of motor mounts used will need usually need to be opened up along the top and rear for the BBKs, possibly at the front as well if using Hookers.

Good luck,
Jeff

[AC Bill]

Jeff hit the nail on the head. Do the splash shields first!
You will also be surprised when you actually put your side pipes on, that the ends of the header, which initially appear to be badly out of line, are not that bad after all.
I found the best tool to open the cutouts was a small drum sander on a drill. You can easily maintain the corner curvature in the cutout, and it removes material pretty quickly.