Date:         Wed, 11 Jul 2001 19:18:09 -0400
Reply-To:     Timothy Hannink <tjhannink@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Timothy Hannink <tjhannink@EARTHLINK.NET>
Subject:      S&S Header Installation
Content-Type: multipart/alternative;

I installed my S&S headers last week replacing the original exhaust system, along with new motor mounts and all new coolant hoses in the engine compartment. I opted for the "High Performance Silver coating that S&S offers as an option and ordered them through Van-again. Like Ken said in a previous post, they were individually bubble-wrapped and well packaged in a sturdy cardboard box. 
They didn't come with any instructions so I ventured out to install them on my own. The fit of the front pipe and the pipe for the right rear cylinder was excellent, they bolted right on. When I test fit the pipe for the left rear cylinder, the mounting flange was about 1" away from the head itself, but aligned correctly. I ended up cutting about 1" off of the slip-fit end and bending the pipe until it fit without having to apply any tension. I used some exhaust joint compound on the two slip fittings. 
I have put almost 800 miles on the system since last week including two 200+ mile non-stop runs to South Florida from Miami. The pipes look like new with no discoloration.
I re-installed the stock muffler and cat with new gaskets due to time constraints. When the S&S muffler did arrive, I did a test fitting and found that using the muffler mounts, the muffler flange was still over an inch away from the cat. I re-installed the old muffler and am looking for a stainless turbo muffler that duplicates the stock one.
I put up some photos of the headers and my new bike rack at the following location:

http://y42.photos.yahoo.com/bc/tjhannink/lst?.dir=/Vanagon&.src=ph&.view=t

A couple of other things, all of the hoses I replaced in the engine compartment were original, and I couldn't find any soft spots or deterioration on any of them. If this new set lasts 14 years and 180,000 miles, I will be happy, though I will probably change them out long before then. The original owner had replaced all the cooling system hoses in front of the firewall at 11 years/125,000 miles because of a hose failure. The thermostat housing itself had deteriorated where it connects to the cylinder head, so that was also replaced (BTW the o-ring is the same size as a large end pushrod tube o-ring of a type 4 motor). I flushed out the heater and radiator loops from the thermostat/coolant distributor connections.
I had jacked up the back of the van about 10" so I could work on it in the garage and still open and close the garage door. I started it up on the stands to check for leaks and had none, so I let it warm up, then added coolant to the tank with the engine speed at 2500 rpm. I test drove it and it didn't overheat so I felt good about it until I read the messages last weekend relating to overheating at highway speeds, knowing I was driving to South Florida early Monday am. So I got it warm, ran it up on a small hill and bled it the Bentley way, but got no air of any kind out of the radiator, only that lovely orange Jell-O looking dexacool..
I installed the 80 degree thermostat and now the temp. gauge needle stays just to the right of the LED when I am in motion and just to the left when I am in stop and go traffic.

Tim Hannink
Winter Park, Florida
Goldibox - 1987 Wolfsburg Edition Westfalia Camper
http://home.earthlink.net/~tjhannink/

 


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