I bought One

[BDRCobra]

I tried the crappy tail pipe expanders at the Auto Zone etc and broke the made in China tool in 2 minutes. I took the header and side pipe off the car and took it to a muffler shop. They have a hydraulic pipe expander. In no more than 5 minutes I had the header pipe expanded. I had the side pipe with me so I could test fit during the whole process. It is the only way to do it. The guy did not even want to charge me since it took him no time. I tipped him $20.

I am 90% confident this will work. If not I will do the flange solution. Taking the passenger side header and exhaust pipe was about 30 minutes, the driver side was a little longer since I had to slide the steering column back to get the header off, an hour. If I had it to it again I could have both off in 45 minutes.

Incredible difference in the sound. Make sure you clean and remove any burs on the male piece of the header, there is no reason it cannot be a slip fit .005" if both pieces are round and not damaged.

[BDRCobra]

In my previous post I said 90% confident it will work. It is definelty working now and I should have 90% sure it was a permanent solution.

[Cashburn]

Good to hear. That is the way to do it. Some expander tools are not up to the task, glad you found a better way to do it.

The other tip is to cut the welds between the pipes on the side pipe. This allows the pipes to move individually to meet with the header pipes better and it allows a better fit.

[oncebitten]

I have the issue with passenger side header. Haven't talked Reg or Frank about this issue. I now have what I call clutch shutter. When on slight incline and letting out the clutch the car begins to shake. Any Ideas?

[Revman]

Is the high beam relay that you guys are talking about the round, or cylinder shaped, 20a device located on the fuse panel?

[Gun Doc]

Revman,

The high beam relay is behind the passenger kick panel, attached to the fuse box (forward edge) with a wire tie. It is square and has five wires attached to it.

I just replaced mine last week.

Gun Doc

[thunder1]

Part# VW 111 941 583 but you can use a standard Part# LR35
vw part $50.00 standard part $27.00 at parts store
ED

[CHANMADD]

Try these links.
http://store.summitracing.com/partde...5&autoview=sku

http://store.summitracing.com/partde...5&autoview=sku