Megan racing headers not aligning with magnaflow

[E46m3zcp]

Hey everyone,

I'm not really sure what to expect from the forum, as this is a pretty simple yet frustrating situation. I ran the MagnaFlow catback with the stock headers for some time, no installation problem - it slid right on. I recently did a rod bearing job, and while I had the subframe and everything else out, I sized the opportunity to swap headers and installed Megan Racing catless headers.

I struggled to slide the Catback into the headers, and now the flanges aren't aligning, and the MagnaFlow's flange is touching the chassis. I spent way too many hours on that, and I am not sure what to do next. Some say loosen the headers at the block - but it's a massive pain now with everything back and it won't make the flange align (you would get some movement in the same plane as the block - i.e. pipe up and down - but I need a rotation along the pipe's axis).

Image below: seen from back to front, what you see is the Magnaflow Catback's flange with the header's behind it. The holes are not aligning, and there's no way to put the flange bolts back. What would you do?

[jayjaya29]

I would remove the bolts to the other header. Then remove the mid section attachment as well. Then I would insert the problematic flange first with the added degrees of freedom and work backwards from there.

[E46m3zcp]

I did just that yesterday. No luck sliding it in manually or even with some light prying. My next step is to insert a thick block of wood between the two MagnaFlow pipes where they are further apart and hammer on it towards where they get closer to separate the pipes further.
I just wonder if I may damage welds or if that will result in some strain on my headers bolt once installed.

Also, I'm not quite sure the magnaflow flange will not contact the chassis/heat shield once it's fitted on, as you can see in the photo the headers flange is almost contacting and the MF's flange is bigger.

Wondering if I should just accept that I bought some bad headers and remove them at this point (I wish it was simpler, I had the subframe off when I installed them, now it's back on and I can't imagine getting them out - although others have done it). What would you do?

[jayjaya29]

Block of wood is a good idea. Fight it until it fits.

[Tbonem3]

This accurately portrays geopoltics.

China vs u.s. - not aligned

[xansabi]

This accurately portrays geopoltics.

China vs u.s. - not aligned

I swear there has already been another thread on NAM3 about Megan Headers that turned into a heated political argument between literally everybody

[terra]

I swear there has already been another thread on NAM3 about Megan Headers that turned into a heated political argument between literally everybody

Yeah let's try not to take it further