Hello everyone,
Thanks for the replies.
I have removed the complete exhaust and I am trying to install the cat-less header from a 2009 touring 96" engine. I have all of the HD service manuals and part manuals (5 total).
1) removed the complete exhaust and right floorboard and rear floorboard support bracket. The front floorboard support bracket looks like a pain to remove/re-install so I did not remove it; I just removed the floorboard and rear support.
2) I do have a torque wrench
3) I replaced the original gaskets with HD part # 65324-83B. Both the FLTRSE3 and the Touring Models parts catalog list the same part number. LarryB, do you know of a different part #? I know when I installed the gasket, it was a tight fit and it seemed to crumple a little bit when they were inserted. I am assuming they are just pressed in with your fingers, no special tool needed.
4) Although the service manual did not tell me to, I applied anti-seize compound to the header studs.
The problem I am having is with the installation of the header. I get the front header started and the two flange nuts in place. When I try and "roll" the pipe on the rear cylinder I cannot get it to lineup or get the exhaust manifold clamp on.
Needles to say at this point the gaskets are all torn up and I am going to have to replace them. I did pickup two sets so I don't have to drive 90 miles round trip to the nearest HD shop.
I would very thankful for any tips on installing this. I will admit that I do not have very much repair experience but would like to learn to do my own work on my SERG. Picking up any tools needed is not an issue; I just want to do the job correctly and as best that I can.
Thank you.