Join Date: Sep 2006
Location: Las Vegas, Nevada
Hmm. I would say maybe cut off that flare add a tube nut, weld the tube nut to the broken piece, tap the header with threads, but even that would require removing the header to access and address the problem, and if you go that far you might as well just weld it right on where it broke off. My only additional tip would be to suspend the engine, and drop the k-member to avoid the hastle of removing the engine from the top.
-1996 Pearl White Thunderbird 4.6 Sport 4v with many mods:
Current Best: 13.583 @ 103.74 10/2014.
227hp/241tq measured on calibrated mustang dyno, tested at full vehicle simulation with inertia enabled, no number skewing.
-2001 White Ford F-250 Super Duty 6.8 V10, 4-door, 4x4, Limo Tint, BFG KO2's, Bilstein 7100 Remote Reservoir Race Bypass Shocks, 6" Spring lift, Kenwood Double Din, K&N Intake, FlowMaster Exhaust
Amber_Murder's Daily Driver.
-2005 White GMC Sierra 3500 6.6 Duramax, Dually, 4-door, 4x4, Limo Tint, BFG Commercial T/A's, Rancho RS9000XL Shocks, Kenwood Double Din, K&N Intake, Banks Monster Exhaust
Chris_Murder's Daily Driver.