Correct headers?

[mack5013]

My dad and I have been slowly (going on almost 10 years, since I was 15) rebuilding a 1977 bronco from the frame up, rebuilt engine and transmission, new suspensions, swapped drums for discs, etc. At the moment, we've got a set of shorty headers from Tom's Offroad installed without an exhaust system (no money = no exhaust system). After a little bit of digging by both of us, we're now unsure now if shorty headers are right for this build. The right header is awfully close to the transmission housing. Someone on facebook said that I might have to bend the headers to fit an exhaust system, and that doesn't sound like a kosher option to me. The engine is a 302 and I intend to have dual exhaust, so I'm looking for a little advice on what type of headers I should be using. And then after that, I would love some recommendations on whether I should be installing my own exhaust system (and what brands) or having a shop do it for me.

 

[jerry]

Can't help, but glad to see your question. Super cool your're working on it with your dad.
Posting some pics might help...

 

[tasker]

what is close? the header or the flange?

 

[mack5013]

Some pictures probably would be helpful, huh? Ignore the dust, we haven't touched it in a while, but in the middle picture, you can see that the end of that pipe is almost touching the housing and it just doesn't sit quite right with me.

 

[Wild horse 75]

Almost touching isn’t touching lol. I would mark where it’s close then take the header off. You can grind down the rib on the bell housing and put a small notch in the flange and give it a bunch more clearance. 1/4” is plenty. Those parts all move together so you don’t have to worry about them hitting when it’s running.

 

[tasker]

THOUGHT I had pics from mine, but had to grind down the collector flange to get mine to clearance it enough to hook up the exhaust
might explain a little better: https://dufftuff.com/wp-content/uploads/2021/09/3106.pdf

 

[DC_Gearhead]

I put long tubes in from Tom’s on a 351. I had to modify the clutch linkage and reroute lines. What you have is not surprising to any of us as you can see. Nothing on these Broncos is bolt on without a little modification. To me it looks like you’ll be fine with a little clearancing.


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[EPB72]

Almost touching isn’t touching lol. I would mark where it’s close then take the header off. You can grind down the rib on the bell housing and put a small notch in the flange and give it a bunch more clearance. 1/4” is plenty. Those parts all move together so you don’t have to worry about them hitting when it’s running.

Thas /\|\|\,,,and you could also take a pry bar or pipe and give it a little persuasion probable get a 1/4 inch or so

 

[mack5013]

ah okay, that makes me feel better. Thank you!

Next question: Where do you recommend getting the exhaust system from?

 

[tasker]

Your choice, I went with a Duff two into one and a Magnaflow muffler on one, will need to be custom bent on my other rig

 

[Shimmy]

I'm happy with my Duff dual exhaust (borlas) and TBP long headers. I think you'll like their 2-1 setup. Keep in mind if you bend your shortys you'll likely need to tweak any off the shelf kit.

 

[mack5013]

Sweet, thanks for help guys, y'all are awesome

 

[mac0424]

New question - Does anyone know of a vendor that sells a dual exhaust system that bolts directly to the BC Bronco shorty headers? Thanks

 

[DirtDonk]

Some pictures probably would be helpful, huh? Ignore the dust, we haven't touched it in a while…

Hey Mack, any reason you changed from the original combination/proportioning valve, to an earlier H-block on the frame?
Just curious.

And is mac0424 the same mack5013?

 

[bmbm]

Mark on header where too close, remove header and use a ball peen hammer to gently increase distance additional 1/8". Personally I would not worry about that but would be concerned if header is very close to the starter.

 

[mac0424]

Hey Mack, any reason you changed from the original combination/proportioning valve, to an earlier H-block on the frame?
Just curious.

And is mac0424 the same mack5013?

No, not that I am aware of.

Should I change my headers to get a quality, complete dual exhaust system?

 

[DirtDonk]

Should I change my headers to get a quality, complete dual exhaust system?

Since you started by saying “new question” and your username is close enough to the OP’s, I think you should actually start your own discussion thread on this subject.
Less potential confusion (even though it is close to the same subject) and might even get more direct and helpful answers.

The BC headers are pretty nice and should do the job for you. I don’t know if there are any bolt on dual exhaust solutions however.
If you want 100% bolt on, then you may have to change headers to someone that offers both the headers, and the dual exhaust kit. And then hope that it fits your specific Bronco.
Which often is not the case. As you probably read already.

I would still start your own discussion though. That way with the correct title you can find out who’s done similar to yours, and if there are new options, I’m not aware of.