Pacesetter header troubles

[harofreak00]

My Pacesetters are giving me troubles. Just recently they started to disconnect at high throttle, not even WOT. They are disconnecting at the 2-to-1 connector circled here. The connector is blown completely off the rear header and crossover pipe. I have had this happen to me several times now, and each time I just go under there, connector it back up, and tighten the clamps as much as I can before it started to feel like they are going to snap or crush the pipe.



Here is a picture of the supplied clamps. They appear high quality to me, but I'm no expert. How tight can I make these before they snap or begin to crush the pipe? Is there anything else I can do short of welding it in place? I'd like to make it easily removeable like it is... those bolts on that 3-bolt flange are NOT easy to access.



If I was still into modding, I'd probably just look for a pair of SLPs or TOG, but the performance mod bug has let go of me and I dont feel like dumping the cash on them. I also dont feel like going back to stock cuz that would just suck.

Here is a video of one of the first times it blew on me.. I was actually making a performance video and it just happened. It happens much sooner now, more around 4k.


Here are some more pics. This one shows how the exhaust was leaking before it blew off.


This one shows everything in place after it was fixed. Don't mind all the Ultracopper RTV on everything.


And here is a pic of the most recent blowout.. you can see that it blows the exhaust backwards and then it drops.

[Allmachtige]

The front header is a bit high, I dunno if the ZZP kit corrects this but I guess see if you can get that collected bent down.

BTW the bit about you being done with performance makes me proud.

[2000Silverbullet]

It looks like the crossover connection has a loose fit. Have you tried wrapping the male fitting with something to tighten the fit? Maybe some aluminum or muffler tape.
Another possibility could be to have the male end expanded at a muffler shop. They would need both pieces and it would be tricky.

[Larz01]

Get different clamps; like the ones in the pic AKA: Torca Accuseal Clamps.

[viper8907]

Get different clamps; like the ones in the pic AKA: Torca Accuseal Clamps.

Those are the ones that SLP's come with. They look like they are pretty high quality also.

[harofreak00]

Thats the advice I was looking for, thanks!

Know where I could find these clamps locally? I don't feel like getting them shipped to me.

[GonneVille]

Probably any performance shop will have them, or any muffler shop. Those T-bolt clamps you had on there are completely the wrong kind of clamp for exhaust. They're only meant for intake, or other areas where you're clamping rubber, silicone, or soft plastic tube to metal pipe. For exhaust, you have to use either those types of clamp, or a U-bolt clamp, to get the necessary force to actually force the outer pipe to tighten on the inner pipe.

[harofreak00]

Local exhaust shop special ordered some 2.5" Torca AccuSeal band clamps. They normally carried 3"+ sizes, but nothing small like I needed..must be for big truck exhausts... They are having them overnighted, I can pick them up tomorrow morning at 8am. Thanks for the help guys, I'll let you know how it goes.

[PDXGTP]

FWIW, I have seen this on several of the Pacesetters and what I have done is...
Put the two in place 100% without the clamps, nice and even, high & tight. then spot weld the rear header to the Y pipe. then remove the rear header and weld the two solid, make um one peice.
Then use a clamp on the cross over pipe only.

This way they will no longer fall like they have been.

[harofreak00]

Thats a good idea. If these new clamps fail I'll try that next.

[PDXGTP]

Thats a good idea. If these new clamps fail I'll try that next.

That's what I said, then the next car was Bob's.. you know, Mr. EchoSSEI.
he doesn't have those problems anymore.

Looking at Paul's comment, we did that too actually, I used a pipe expander and tightened the fit between them too.
another thing I did was cut a 3/4" grove in both sides of the pipe.. this will be hard to explain so I'll use a picture.
Like this... this way the pipe will clamp down ighter.
We also sealed it with copper RTV before the pipe got clamped down so no exhaust leaks seeping from the gaps.. if any..

[harofreak00]

The ZZP version I got is already like that. You can see the notches in the first pic.

I just got back from the exhaust shop. Sadly they ordered the wrong clamps. They ordered something like this, about 4" wide. They wanted $43~ for the two clamps.


This is what I had them order... had to point out the picture. The new ones they ordered are about 1.25" wide. Hopefully they will show up tomorrow otherwise its monday... ugh

[SuperSLE]

Screw the clamps and weld it like I did .

[PDXGTP]

Haro... of the two clamps I like the Torca clamps, which are the clamps you ordered, don't like the other kind.

Get-er-done.

[gigolo]

Screw the clamps and weld it like I did .

like I did too then wait for the front header to rust through like mine especially if you are in a salt/snow state like me

[2000Silverbullet]

I hope you don't drive your Trans Am in the salt!

[harofreak00]

Got the new clamps installed this afternoon. I could instantly tell they were holding much better than the old ones. The test drive confirmed that. Several WOT runs and not a leak. Thanks for the help guys.

[excessive81]

where you buying pace setter headers for 2000+ cars?

[harofreak00]

They are the same Pacesetters as all the others. You have you get a W-body trans dipstick tube.

Looks like ZZP is out of stock right now: https://www.zzperformance.com/grand_pri ... php?id=598

[crzydmnd72]

Just a thought, along with loose clamps, is the motor rocking much under acceleration? Could that be a factor?