Herb,
 
  I found out that the GM aluminum heads on the ZZ502's have a slightly raised exhaust port also.  Makes finding an exhaust/header gasket very challenging.  The headers I went with are the Sanderson C7 (full length) headers with the GEN VI header flange.  Yes, there were fitment issues.  Each side has one or two pipes with "dimples" for clearance. 
 
Kent Lewis
'68 Malibu  ZZ502/502
ACES #5102 
----- Original Message -----
From: Herb Lumpp
Sent: Saturday, February 19, 2005 6:59 AM
Subject: [Chevelle-list] Issues w/ aftermarket heads

As most of you know, I bought a set of AFR heads for my Elky.  I've recently confirmed some info regarding aftermarket aluminum heads you should be award of before purchasing...
 
In the quest for higher flow numbers, the aftermarket head manufacturers are altering their castings.  What this means is that not only are the exhaust ports and spark plug holes relocated, but the majority of available heads are wider than a factory head.  This might not sound like a big deal until you try to get headers that will fit the heads and your car.
 
Not too long ago I bought a set of Stahl headers and much to my grief, once bolted to the heads, I wasn't able to get a socket on 3 of the passenger side plugs.  Since the engine wasn't in the car, I have no idea wether or not the headers would have fit the chassis.  Thankfully Stahl let me return them for a refund.  Now Stahl is in the process of building another set using their second design with an adjustable jig and one of my AFR heads for accurate dimensions.  Needless to say, these new headers won't be cheap.
 
After talking with Jere Stahl and Ed Henneman (Headers by ED) they both confirmed that the head manufacturers are avoiding this topic.  The head manufacturers aren't the end users so they keep changing the castings and "forget" to mention to potential customers there may be a problem fitting headers.  I guess if you're building a completely handcrafted race car, a set of one-off headers isn't a problem.  However, if you're building a car using a factory chassis, header fit becomes an issue.
 
For those of you with crate 502 engines that have Chevy aluminum heads, were there any problems fitting headers?

Herb Lumpp
http://users.adelphia.net/~hlump/index.htm

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