I finally got my 383 up and running (with Dyno Don's headers) and I've found that no matter how I route the wires, the boot on the #8 plug gets too hot and starts to melt. I even have those little heat-resistant spark plug wire shields, but that turned black and the boot is still turning white.

I was thinking about buying some of the header wrap, but I had a couple of questions:

1) Will it help keep the boot from melting? There is already very, very little clearance between the boot & header, adding wrap might make them touch.

2) Is it okay to wrap just the tubes that are giving me problems or should I wrap the entire header?

Thanks!

 

How much gap is there between the pipe and the boot? Make sure you don't have an exhaust leak cooking it.

 

The exhaust should never get that hot, there has to be something wrong with the tune.

When the engine is running right the exhaust at the header will be around 300 to 400 degrees.

 

I'll have to check what the temp is at the header if I can, I don't really know.

The car will definitely have to be tuned - I ordered a chip via the internet but have yet to find anyone local that can do a tune. I might be stuck doing the "data collect/send chip & data back" method of tuning. I know that's not a great way to do it, but it might be all I have.

Out of curiosity, what could be happening tune-wise to make the exhaust get too hot? Just wondering what other symptoms I could look for to help diagnose the exhaust being too hot if I can't find a temperature gun to use.

No, there are no leaks - the only part of the boot that is affected is the back, the part that is close to the header. Plus, you can't hear or feel any leaks.

 

A lean condition and or retarded timing are a couple things that will do it.

Mark.

 

Okay, thanks. I just spoke to my brother (my car is at his shop), he has an infrared heat gun so I should be able to see how hot it's getting.

 

Header wrap and DEI plug boot protectors will work. My turbo car sees much higher temps than any n/a motor sees and mine are fine. As long as they dont touch the header they survive. My surface temps exceed 700 deg on my temp gun. Exhaust gets hot but shouldnt melt wires if it doesnt directly touch header and also when you use good heat shields.

http://m.summitracing.com/search/Pro...otect-A-Boots/


Check spark plug for rich lean mix and then play with timing to control some of the exhaust temps. Not sure what your combo is but timing usually helps as too little will burn fuel mix inside header tube creating hotter temps

 

Header Wrap Looks Ugly But It Works

 

Those are the boot protectors I have.

I'm starting to think that the boot protector was touching the header & transferring the heat to the boot; the problem is only on one cylinder.

Anyway, I'll check the header temperature later and go from there. Thanks for the replies.

 

It likely is touching. Theres no way it should be melting thru those boots if its not touching. Is the boot protector cooked white and crispy? If so it must have touched for a long while to melt the plug wire

 

The boot protector is black on the outside. The boot itself is white and melted...like maybe the protector melted to it?

 

Hmm mine was opposite when i melted a wire that was touching. I have red wires with red protectors. Protector turned whitish and plug wire was burnt black.