Another self inflicted injury...measure twice, yada yada yada

[oldguy668]

I make a living by checking other peoples work. So why don't I check when I'm on my own project? I bought a MK4 kit partially assembled about a year ago. Some of the aluminum had been drilled, powder coated or modified. I noticed the driver's side inboard footbox panel had a bump-out for the throttle foot, which I thought was a good idea. I had seen others done that way and probably would have done in myself if it wasn't already finished. I also bought a set of used BBK stainless unequal length headers. I assumed that the headers were a fairly standard dimension and that the widely-posted footbox mod would work okay with them. In hindsight, I should have dropped the long block and headers in for a test fit before I had the headers coated and spent hours finishing the interior of the engine bay. So, here's what I have:

46804

Looks like the header and footbox aren't going to play nice. Can anyone suggest an alternate header that might not stick out as far as these do? I'm tempted to run it this way with a piece of exhaust wrap as a pad until I pull the engine in about a year to do the bottom end (289 to 331). I can then remove the bump in the panel. Any other suggestions?

[DaleG]

May be tricky from an access standpoint, but could you cut out the bump with a small cut-off wheel from the footbox side and patch it, also from the inside?

Or, with a cut-off wheel and sawzall, cut horizontally across the top next to the footbox and down at the front of the bump, and push the bump inwards for header clearance?

[oldguy668]

I went upstairs and took some of "poppie's medicine" as the grandkids call it. The recipe is 3 ounces of Midleton Rare, 2 ice cubes and a reclining chair....works every time. It looks like the previous builder got everything right except the overall height of the bump-out. It's a good 3 inches higher than is has to be and interferes with the header at the top 1.5". Now that I have "relaxed" a bit, I guess Ill yank the motor out tomorrow and trim the aluminum. I'll hide the surgical scars with a piece of silver high-temp insulation.

[bucketlist]

cut header at flange bend in reweld grind smooth, silver header spray, the coating really does not stay pretty that long, and it is in a out of way place.

[skullandbones]

Hi Oldguy,

If only the back header tube is involved I would do a little body work on the panel. You can use a ball ping or body hammer and a block on the other side and massage the panel until the shape is opposite the header curve. If you mark the area on all four edges of the tube you will get an oval shape area to work on. After it is done you would not even be able to see the mod like it was designed that way. You would probably have to have some help from the inside if you don't have access from the top of the foot box. Just take your time.

Good luck,

WEK.