BBK LT (full length or long tube) Header Install

Here are the BBK 1 5/8" primary tubes, which are VERY smooth both on the inside and out. I also opted for the Jet-Hot ceramic coating which not only looks good but will keep the heat inside the header and out of the engine bay better than normal SS does. The X I drew on the header denotes the small abnormality in the single-piece flange I discovered, it is .005" of a gap, but the gasket will make up this difference easily.
These are the stock headers, notice how they are pinched off at the flange, which restricts flow big time. And the unequal length of the tubes leaves some cylinders hurting for flow.
Here are the BBK ports on the laser-cut flange. The flange is perfectly straight as checked with a straight edge, and the port welds themselves have been massaged with a grinder and smoothed out for a good flow transition from head to manifold. Note: the little bits you see on the flange are cardboard box pieces, the flange itself is perfectly smooth at the welds on the inside of the primary do not protrude in any way to hurt the seal.
As you can see, the stock header ports are smaller and the combination of the pinch and bad welding leaves little room for exhaust to escape quickly.
I was wondering why over my last tank of gas, my car got very sluggish and turned about 15mpg (I normally get 21-23 at least). Well this could be why. This is the worst burned wire I have had yet, it burned completely to the core, and with a little pinch of my fingers, the wire almost snapped in 2 pieces. If you look above it, you can see the gas-soaked spark plug from the #3 cylinder. Ouch. The O2 sensors are there for comparison, the whiter O2 is from the driver's side, the side which had all cylinders operating normally. The darker O2 is the one with the dead cylinder which had excessive unburned gas in it. The very top spark plug is a normal one but it must have rolled out of the way as I took the picture because you can't see it.
Good riddance smog pump, hello Auto Specialties Smog Eliminator kit for 94/95 5.0L Mustang GT and Cobra©. This piece looks nice and clean and frees up quite a bit of weight on the front end, I was surprised. Not to mention eliminating the clutter on the passenger side near the plugs. One small thing was bad with this piece, the bottom bolt hole was milled slightly off and I had to force the bolt in. You can see that I wasn't able to get it all the way in, as I was creating new threads in the billet aluminum. I guarantee its not moving anywhere now though, hahaha.
Here is a picture of a terrier on a washing machine.


click here to go to page 2 of the BBK LT headers