I installed the OBX 4-2-1 header yesterday; it was a bitch to put on but a lot of fun. Did anyone else have to permanently remove the round bar brace that is goes under the starter & a/c compressor? There just wasn't any room with those 2 pipes and so the brace had to go.
Also to anyone that did their own install, did you have any issues with the flanges for the cat, in that, the cat doesn’t come with pre-welded flanges for a direct bolt on application? The Magnaflow cat is 2 ¼” ID/OD and the down-pipe’s flange had a 2 ¼” hole diameter, which was fine. But, the RKSport cat-back piping flange that bolted up to the cat had a hole diameter of 2 ½”. First I had to find a place that sold these 3 bolt triangle flanges, then get a small 2 ¼” to 2 ½” adapter fitting and have it welded onto the cat. Now the cat will bolt right up to the system but it was a lot of trouble to go to and those flanges were hard to find.
Now I’ve just got to clamp on the muffler and it’ll be finished. Hopefully it’ll be a lot quieter with this Dynomax Super Turbo muffler. Before, it was too loud (for my taste) with a Flowmaster 50 series.
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'95 Cavalier</a></B>
youll prob need a resonator as well, just from what most have been through...
and the bar, many have had to remove it
i put the same header on my 96 2.2 auto last weekend....had to take off the starter and the coolant inlet where the thermostat is.......guess it was time for new coolant anyway
as for the flanges, i found a 2.25 flange at autozone and i don't have a cat so it was just a straight weld job
did you have any problems reinstalling your front o2 sensor.....i had to monkey with the starter wires to get them out of the way
Autozone had the 3 bolt triangle flanges? Crap, I went to every other place but them: Salvo, PepBoys, Advance Auto Parts, and a few smaller part stores.
No probs with the O2 sensor, it was in the exact same place as it was in the stock manifold.
<a href="http://users.erols.com/spider-man" target="http://users.erols.com/spider-man"><img src="http://www.j-body.org/registry/bronx/personal_pic.gif">
'95 Cavalier</a>
i didn't have any trouble with the install other than accidentlly breaking off the bolts from the OEM b pipe into the OEM cat... which is why I am running a 2.5" test pipe right now... note to self, never use impact on exhaust flanges.
I was a retard, and now I'm permanently banned.
Quote:
oh damn its spidey! 
Long time no see Omega!
<a href="http://users.erols.com/spider-man" target="http://users.erols.com/spider-man"><img src="http://www.j-body.org/registry/bronx/personal_pic.gif">
'95 Cavalier</a>
i'm in the process of installing my obx 4-2-1 and ran into a problem...where the header connects to the downpipe...there is a rubber piece on the axle that is keeping the flanges from meeting ok...so what i guess i'm going to have to do is weld those pieces together and get rid of the flanges...anyone else have this problem and what did you do to fix it?
welding those pipes together is going to be a pain in the event you ever need to take that header and b pipe out because it will of course be one piece and won't come out easy. but if that is what you have to do, i guess it's what you have to do.
I was a retard, and now I'm permanently banned.
yeah i definetly don't see another way of going at it...i wish i woulda taken pics to post and get opinions...too bad my car is at my friends house in pieces haha
i just don't see how the 4-2-1 header could be hitting the axle on a 2.2
I was a retard, and now I'm permanently banned.
Grillrd: yeah, the flanges on the header came awfuly close to rubbing up against that half-shaft bushing thing but I moved the flanges around so that there would be enough clearance. You don't want to weld those pieces together because that would be a pain in the @ss if you ever had to remove the header for any reason (manifold gasket replacement, head gasket replacement, or anything that would require the removal of the exhaust manifold). I don't even know what that rubber piece is for, except for maybe keeping things from touching the half-shaft.
<a href="http://users.erols.com/spider-man" target="http://users.erols.com/spider-man"><img src="http://www.j-body.org/registry/bronx/personal_pic.gif">
'95 Cavalier</a>
i found out it's a dampener...able to be moved...so i just slid it over. have everything on now...didn't put the resonator in...don't mind the popping too much....definetly feel the difference
I installed mine in about an hour and took it to the muffler shop and had to have my downpipe bent a lil and welded to my magnaflow cat. Easy fix!
