Spark Plug Boot Loves Header...
 

Ok, so just looking for some advice or ideas here. I have a spark plug boot touching one tube on the driver's side (#5). I have shorty header plugs. With the spark plug boot on, the header tube not only touches it, but presses against it. I had a cheap set of autolite wires on here for awhile and to remedy the problem before, simply removed the boot. Since the terminal didn't touch, no arcing...but looks like crap and is not the best idea. Finally got a nice set of the wires that I wanted and thought I could do something a little different instead of removing the boot this time.

Specs: '82 Trans Am, 327, new 8mm Mallory Pro Sidewinder wires with 90 degree boots. I have stainless steel headers but I have no idea what brand they are as there are no markings on them. Only one tube touches, the rest of these headers have decent clearance for all the spark plugs and boots.

Here's what I did (or what I'm trying rather) after installing the new wires. I put some fiberglass 1,200 degree fire sleeve around all the wires around the headers (for good measure), then used a DEI fiberglass boot over the wire/boot that is touching the header tube. So, I have header tube pressing against DEI boot, pressing against spark plug boot. Will I still have problems here? I have NOT started the engine yet to run/test for heat damage. There's literally no other way for clearance. I have to take the header back just to get the boot on even with the short plug.

I've never used the DEI boots before, so I'm curious how they work if they are touching if anyone has dealt with this before. I'm tempted to take the header off and beat the crap out of it in that spot for clearance otherwise, I just hate to do that.

Re: Spark Plug Boot Loves Header...
 

I had to run a similar setup on one of the plugs on my s10. Havent had any issues so far, but keep a check on it, the fiberglass sleeve will eventually get brittle where it touches.

Re: Spark Plug Boot Loves Header...
 

Yeah, that's what I was afraid of, the boot getting brittle or transferring the heat straight through to the rubber boot and melting it anyway. I see so many conflicting posts about these DEI boots across different boards. I may just end up taking the rubber boot off the wire again and run fire sleeve all the way down so it's not noticeable at shows. I know one thing, as soon as I get my pennies saved, these stainless headers are getting replaced. I found out what they are on here while searching and apparently they are Flowtech knock-offs or they could be actual Flowtechs. They make it impossible to clear a boot on #5.

Re: Spark Plug Boot Loves Header...
 

DEI boot protectors work well but if its still touching heat will eventually get thru and melt plug. Happens on my turbo setup but my exhaust temps likely are higher.

If you wrapped the header tube with fiberglass and installed boots on the plugs, it will take awhile before heat gets to it. It may never get to it, hard to say. Only other thing to try is toto sandwitch a piece of ceramic material between it to keep heat transfer away. Or dent the header tube some. Dont need much clearance with the boot protectors but cant be directly touching or they will wear out

Re: Spark Plug Boot Loves Header...
 

It definitely touches. Heck it presses up against it even without the DEI boot on there. I may end up just taking the rubber boot off again. I really don't want to destroy my expensive wires and the boots slip right off and go back on quite easily which makes it a breeze to get the fire sleeve on there.

Re: Spark Plug Boot Loves Header...
 

Cant you shave some of the material off the boot?

Else take boot off throw in some heat shrink wrap to protect open wire and keep the dei sleeves on

Re: Spark Plug Boot Loves Header...
 

That's probably what I'm going to do, just take the rubber boot off and protect the wire with the DEI boot and see if that clears. I have a feeling it will still touch. As soon as it stops snowing, I'll get out there this evening and try it. The thing that sucks is I have to take the header off to even get to it. That will teach me to research headers better next time.

Re: Spark Plug Boot Loves Header...
 

If its that bad with short plugs then dent the tube or buy new headers that will work. What type heads you have? Plug angle must not be friendly to thirdgen headers

Re: Spark Plug Boot Loves Header...
 

another possible option is to find a cheap set of used headers, chop the tubes off and grind the flange flat. use the flange in between your headers and the head. of course youll need 2 sets of gaskets and maybe some longer bolts.
just thought id mention it as another option. but id probably just ding it with a hammer, lol.

Re: Spark Plug Boot Loves Header...
 

I have 350 HP camel hump heads on a 327. The plugs are straight out just like the old 305 was. The sad thing is, it's just the one tube. The rest of the plugs clear fine. I'll see if I can get some pics of how close it is tonight.

Re: Spark Plug Boot Loves Header...
 

LOL, i'd throw the headers across the yard before I had to do all that, then go pick them up and throw them again.

Re: Spark Plug Boot Loves Header...
 

You should be using 90 degree plug wires and shorty plugs. You can try and dent/bend the headers. Also, try the spark plug boot protectors too.

Re: Spark Plug Boot Loves Header...
 

Did you read anything that was posted? Lol

Re: Spark Plug Boot Loves Header...
 

Sorry, didn't get any pics. I got sidetracked last night when I was browsing craigslist and found a guy selling a near perfect factory ttop headliner covered in black material for $60.00 an hour away from me. I just basically dropped everything including eating supper and went and got it.lol I'll see if I can take a pic of the header and spark plug tonight if I don't find any more awesome thirdgen parts to go get.haha

Re: Spark Plug Boot Loves Header...
 

Must be some of those Import knock off headers.

Best bet is remove the plug, and try and dent the tube to clear, IMO.

Re: Spark Plug Boot Loves Header...
 

Where in KY are you? I'm close to Louisville!

Re: Spark Plug Boot Loves Header...
 

I'm about 10 min east of Owensboro. I drove to Rough River last night in a FLASH to get that headliner.lol

Re: Spark Plug Boot Loves Header...
 

Yea after searching on here the other night, I found a thread "ebay headers" I think and they look just like the ones I bought. Other than that #5 Plug issue, I'm ok with them. They are actually made really well for the 139.00 I paid. Was planning on upgrading eventually and the more trouble I have with this #5 tube, the closer I am to doing it.

Re: Spark Plug Boot Loves Header...
 

You're a haul from me for sure.


I think you might be able to dimple it without removing the header. Liek you said, they'll be good enough for now. but I would at least get an air gap between the tube and the boot.

Re: Spark Plug Boot Loves Header...
 

The headers maybe were made for angle plug heads and thats why its hitting. Like said try to dimple it. These are the shorties right? Could you remove that header to dimple tube? Driver side should be abit easier than passenger side if you have ac.

Re: Spark Plug Boot Loves Header...
 

Yea, they are shorties. I may try to dimple it. The beauty of these headers...take out the flange bolts from the head, unbolt from y-pipe, take out two or three plugs on each side and lift them right out of the engine bay from the top so easily it will make your head spin. I've never had headers that would come out the top. I'll throw some pics up later this evening.

Re: Spark Plug Boot Loves Header...
 

I overlooked the fact he had 90 degree boots already. LOL

Re: Spark Plug Boot Loves Header...
 

Why don't you get some good name brand headers used? or you could always get the ones Dyno Don has. They look really well made.

Re: Spark Plug Boot Loves Header...
 

Here are a couple pics of the headers I have (on the engine loosely before install last year):

https://img191.imageshack.us/img191/9948/headers3a.jpg

https://img259.imageshack.us/img259/2843/headers4a.jpg

DEI booted plug on #5:

http://img839.imageshack.us/img839/6268/img1199xq.jpg

DEI boot pulled back. It's difficult to tell in the pic, but the header is actually pressing against the boot with some force:

http://img834.imageshack.us/img834/396/img1210xxz.jpg

http://img825.imageshack.us/img825/1886/img1204yl.jpg

It's worth noting that no matter which way you rotate the plug wire, the header is pressing into the top of the boot. I guess whoever designed these headers figured that you didn't need #5 on most V8 applications.lol Every single plug but this one clears by more than enough. I wonder if the REAL Flowtechs are like this on #5 as well?

Re: Spark Plug Boot Loves Header...
 

Ok header gurus...how does one dimple or dent in a header tube properly? I'm ready to go ahead and do that which will work until I can get a nicer set I guess. I can take this header off in like 10 minutes have it out of the car and upside down and perform surgery on it.

Re: Spark Plug Boot Loves Header...
 

mark it with a sharpie. take it off and dimple it with a ballpeen hammer. its about all you can do at this point,...well except for doubleing the flange, or getting different headers.

Re: Spark Plug Boot Loves Header...
 

Take a torch, heat up the area, hit it with a hammer.

Re: Spark Plug Boot Loves Header...
 

Those headers probably fit angled plugs better but do as said above, heat it and smash it down

Re: Spark Plug Boot Loves Header...
 

Well I'll give the hammering a try this weekend. I'm definitely going with better headers later, but I'll give this a go.

Re: Spark Plug Boot Loves Header...
 

You any good with a welder and cutting/fitting pipes? Could relocate that primary to where #3 fits in at the collector and bring 3 into 5 at collector.