Header question ( long tubes)

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0xDEADBEEF

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Maybe bash that tube in a little bit. I think the physics of the heat radiating off the tube follows the inverse square law, so even creating just a little bit more distance can have a large impact.
 

L31MaxExpress

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I think you must be using different engine mounts. The basic swap non adjustable "stock location" mounts are made two different ways. I ran into this on the 87 G20 when I had a 6.0L in it. Unknowingly the first set I tried on it were stock position relative to the front of the engine and the transmission was about 2" from mating to the engine. I ended contacting the manufacture mad as can be but was cordial with them and they explained my error. I picked up a set of adjustable mounts from them. In the process I found that the same manufacturer made the non-adjustable mount plates in two different part numbers. One part number was stock position relative to the front of the engine and the second part number was stock position relative to the bellhousing. On the G20 van in the more forward mounting position the speed engineering headers were hitting the forward unibody "frame rail" of the van. In the rear position it had loads of clearence. They were C10 swap headers but still fit the G-van after setting back the engine in relation to the stock SBC bellhousing location. If you have the forward mounting position mounts that primary tube will sit about 2" farther forward than the rearward mounting position mounts.
 
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L31MaxExpress

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Another thing, the transmission absolutely can make a difference IF you are using adjustable mounts and locating the engine in relation to the transmission crossmember and transmission mounting point. In regard to bellhousing face to mount, the 6L80E is slightly longer than the newer 4L60Es and substantially longer than the older 4L60Es. The mounting point on the newer 2 piece bellhousing 4L60Es moved compared to the older 700r4/1-piece bellhousing 4L60Es. Because of this I actually bought a 1998-2002 Express 4L60E crossmember for my future 6spd automatic swap in my 97 van. The newer crossmember bends slightly to the rear for the longer 2 piece 4L60E used in those vans and matches the 6L mounting postion well.
 
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Another thing, the transmission absolutely can make a difference IF you are using adjustable mounts and locating the engine in relation to the transmission crossmember and transmission mounting point. In regard to bellhousing face to mount, the 6L80E is slightly longer than the newer 4L60Es and substantially longer than the older 4L60Es. The mounting point on the newer 2 piece bellhousing 4L60Es moved compared to the older 700r4/1-piece bellhousing 4L60Es. Because of this I actually bought a 1998-2002 Express 4L60E crossmember for my future 6spd automatic swap in my 97 van. The newer crossmember bends slightly to the rear for the longer 2 piece 4L60E used in those vans and matches the 6L mounting postion well.
That may be on Van frames, but on truck frames you just drill new holes. I was able to slot my crossmember where the trans mount is. That gave me enough adjustment to use the original frame holes. But as far as the header clearance on a 2500 the long tubes clear and will need to be Jet Hotted or similar ceramic coating. Wrap may work but with the flex of the engine my guess is the joint count chew into it under torque load.
 

L31MaxExpress

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That may be on Van frames, but on truck frames you just drill new holes. I was able to slot my crossmember where the trans mount is. That gave me enough adjustment to use the original frame holes. But as far as the header clearance on a 2500 the long tubes clear and will need to be Jet Hotted or similar ceramic coating. Wrap may work but with the flex of the engine my guess is the joint count chew into it under torque load.
My point was more if the crossmember was left in stock location and the 6spd bolted to it that the engine would be in a different position than the headers were designed to fit in.
 
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