[Dr K]

Originally Posted by BlackTalon

Sounds like Drk needs to start an" i'm sorry Josh" thread

How about a(n) FU Dave thread, instead!

[realroadrage]

Originally Posted by Jose

I just trimmed that piece to clear the header tubes.

x2, I did the same thing when installing the 993 heat exchanger/custom exhaust from Spike. That piece was causing the heat exchanger hoses to rub up against the axle, so I just cut a channel into it to allow the hose to clear the axle.

[Trak Ratt]

Originally Posted by mscheidt

x2

X3 sounds like the way to go.

[Dr K]

First time on Dorki since early morning - and I went ahead and cut notches. Easy-peasy with a cut-off wheel. Here's a photo of the cut-outs. Didn't yet take a photo of the headers in place. [couldn't upload the photo even at 128K file size...]. Headers went right on. Used the copper lock nuts (speak now if I should change that). Much easier to get to the nuts than the GHL headers, but not as easy as the Porsche heat exchangers (with the correct tools and barrel nuts).

Also removed the old wheel studs (using C-clamp, home-made tools out of pipe, and gentle hammer blows).

Installed new longer ones using same pipe tool as large washer, old lug nut, and impact wrench. Only screwed one up, which hopefully will be fine after I find a die that size tomorrow. Otherwise it's overnighting one, removing the messed-up one, and replacing (hmmmm...maybe I should overnight TWO!).

[realroadrage]

Originally Posted by Dr K

(hmmmm...maybe I should overnight TWO!).

Almost always a good idea unless a high $$$ part.

[HoodPin]

Originally Posted by mscheidt

Almost always a good idea unless a high $$$ part.

X2. And for racing purposes, an inventory of "spares" is a must. Nothing worse than missing a racing session because you didn't have a $2 spare part, especially if you knew it was vulnerable part.

[smdubovsky]

x3. Studs break at the most inopportune time...

If you buggered the thread ends, use a thread file. I think my metric one is still at the office. I'll dig for it today.
http://www.use-enco.com/CGI/INPDFF?P...MITEM=990-3076

[Trak Ratt]

What size did you end up getting? I need some longer ones for the 964. Maybe we can share the shipping? I have some spare stockers if you need any.

BTW Thanks again for checking with Radial about fixing my old wheel AND picking up and paying for the new one

[Dr K]

I got the 72 mm's, just BARELY long enough for 1" spacers (<1 mm sticks out past the lug nut). I'll call you, boy-o, if I need to order. If SMD has the thread file, or I can find a die that size (call to the most likely person already placed), I'll fix what I have.

The tool I made was a piece of 3/4" (ID) mild steel pipe, cut to about 1" long. For inserting the new studs I added a 1/2" piece to make it longer, but that got mangled and I cut a new piece 1-1/2" long and flared the end a bit for the lug nut. The mild steel ended up flaring out with use, so I needed to make another one for the other wheel. I was more careful to have parallel surfaces (cut straight) on the 2nd one and it worked better. I also used aluminum lug nuts for this purpose (the one that I used a steel one on was the one that got messed up), figuring that I'd rather sacrifice lug nuts I have no use for than studs that were difficult to get in and out. I stripped only 1 lug nut, then changed to alternating between 2 different ones to let them cool in between applications.

[Vicegrip]

Unless the threads are smeared into mud you can clean up the threads with a small sharp angled file and some care. Tony K has my Porsche stud sized die if you can't get the htreads cleaned up any other way.