In the process of trying to clearance my new long tube headers I went ahead and started grinding the crossmember on the passenger's side. After grinding quite a bit off I still don't have enough clearance and I'm starting to worry about the structural integrity of the crossmember.

My question is, can I afford to continue grinding? I would need to expand the hole about another 1/4" around plus grind another area on the driver's side.

Pictures are attached. Thanks.

EDIT: The area on the driver's side is part of the crossmember that goes directly below the engine. The area on the passenger's side is part of the crossmember but further back where it connects to the control arm.

 

I would need to grind a notch completely through the metal and of about the same diameter on the driver's side.

 

I wouldn't say its 'dangerously' weaker. It isn't the best scenario to grind on your k-member to make the headers fit. I usually just dimple the headers.....

btw, how old are your motor mounts? if they are original to your 84, then you might want to consider replacing them with some poly mounts. That'll raise the engine up and may help with the headers rubbing the k-member

 

Yep, you're probably using your old motor mounts.....get new ones. That will minimize the grinding.

 

I ended up denting the headers among other things... I am using new motor mounts actually. These headers were a nightmare for my car and I will probably post a thread about my fitment experience in the exhaust section at some point.

Thanks for the replies.

 

What kind of headers are you using?

 

They look like ceramic coated Hooker 2210. If that's correct than I find it odd that I ran those with a stock cross member and had no trouble with fitment. With the UMI k member I have gobs of room. Or is it the stainless works header? Definitely look into new mounts if you are grinding that much. In Traxion's install thread of the 2210s he and Momar talked about poly vs new rubber mounts for header fitment. Check it out, I think its a sticky now.

 

They are Hedman 68466. As I mentioned before, I'll definitely be making a thread about my experience with these... I've gotta get this car on the road as it is my only ride back home from college for the summer so I went crazy and dented and bent them to fit. Depending on how they turn out something like hooker 2210 might be in my future...

 

you could grind off, notch and cut it as needed, just cut back enough to weld a plate over the said area to box it back off for strength.

 

Definitely get a set of hooker 2210. The Hedman have a horrible reputation for fitment. Go to the product review page and look at the reviews.... Members have horrible responses/reviews for them. You can do like Gumby mentioned and cut out a square and then weld in a patch.

 

I dont understand at all, my Hedmans fit great? I dimpled one of them to clear the k-member, but other than that it was fine.