BCB headers and AFR heads

[Viperwolf1]

Well I got my BC Broncos headers in the mail today and they are super nice. However, I mocked them up to my AFR 165's and found I have a problem. The bottom of the header flange interferes with the unmatchined portion of the heads. This causes the bolt holes to be mismatched by about 3/16 in. I either need to 1) grind away on the bottom of the header flange to gain clearance, or 2) find a way to move the header away from the head by about 1/4 in. I don't really like option 1 because these headers are coated and this would destroy the integrity of that coating. Is it possible to use another header flange or some really thick gaskets between the two? Where can I find something like that?

BTW, I also mocked the headers to my old E7 heads and they fit perfectly. Great product, improperly planned application.

 

[needabronco]

I'd almost say to take a sanding disk to the heads and gently clearance just what is need for the headers to fit. If done right it won't detract the value of the heads and most likely would go unnoticed. I wouldn't grind on the headers... Hope you get it to fit, should be a nice combo.

 

[Desert Thrasher]

I'd mill the bottom of the flange instead of grinding on them, if thats what you end up needing to do. Good luck.

 

[broncnaz]

I'd just grind the flange it will be on the bottom its only a small area and I doubt it will cause any problems with the coating. If your not close to finishing your project you might want to call Chuck and see if he would modify and coat a set for you. I'd probably call him anyways and let him know of this I'm sure he will modify his design.

I'd almost suggest clearnacing the heads but looking at some heads I have lying around it appears theres a water jacket below that area and not knowing how AFR casts there heads and how big the water jackets are I dont think I would do it.

 

[Viperwolf1]

I'll call Chuck tomorrow. It was too late today by the time I got home. I don't think I'm going to try to modify the heads. Too much pucker factor with the potential cost of screwing them up. I figure AFR stopped machining them at that point for a reason.

 

[chuck]

I have heard of this problem before. They fit most of the after market heads but not all. The other people grind a bevel on the bottom of the header. Don't do too much.

 

[Viperwolf1]

Chuck,
This is the first time I've had ceramic coated headers. Is there a possibility of the break in the coating (if I grind) causing further separation or damage to the rest of the coating? I'm thinking rust may migrate under it over time.

 

[broncnaz]

There's always the chance but its rare. I've had ceramic coated headers on my bronco since 97 they are fenderwell headers and rocks get thrown into them all the time by the tires I have yet to even chip the coating. knock on wood. As far as rust is concerned that area of the header will rarely ever rust due to the heat. water rarely finds its way to that area but you could try using some high temp paint just to cover the metal. I did have coating peel due to rust but it was due to a bad coating job this was on the lower header tubes and was about 3 months after install I had to get them recoated and havent had anymore problems.

 

[Viperwolf1]

Thanks for the advice guys. I ended up grinding a bevel in the bottom of the header flanges. Grind a little, test fit, grind a little, test fit, etc. I only took it down until I could just get the bolts in with the header flat to the head. Once I add the gasket it'll have enough clearance to prevent any problems.

 

[needabronco]

Ah man you ruined them. They are sure to leak now!




Tell you what send them to me that way you don't have to worry about the bad exhaust leak you just caused...............



Just kidden, looks like that should work, make sure to use a quality gasket and it should be fine. Good luck. Someday I'll be able to afford BC headers.

 

[Viperwolf1]

I sprung for the aluminum gaskets and the new wedge lock bolts. I think it'll be fine. And if an exhaust leak is the only trouble I have with this new motor then I'll be more than relieved.