Muffler install problem

[Kenneth Pagel]

Having issues with installing the muffler/exhaust header on my GTR: Seems the headers will not slip all the way into the head when the end of the header is seated in the rubber gasket at the muffler/header joint. Is the header supposed to butt up against the muffler inside the rubber gasket , or is their supposed to be a slight gap? Also, the muffler/header gasket has a raised lip inside, and I assume the entrance to the muffler butts up against it; doesn't make sense for the header to butt up against the lip. I've tried to install the  header and muffler loosely so that I have room to make sure everything lines up, to no avail. So what am I doing wrong?  These are stock mufflers and head pipes, BTW. Thanks in advance.

[OldSwartout]

The head pipe actually fits inside the muffler about 1-1¼",  the rubber sleeve just seals up the joint. Put the copper/fiber gasket in the cylinder spigot first, then the header pipe flange sits inside the cylinder spigot against the gasket with the collar holding it all in.  I've found the easiest way is to put the gaskets and header pipes into the cylinders with the collars installed just loosely enough so that you can move the headers easily, slide the rubber gaskets and clamp rings onto the header pipes a couple of inches,  then push the mufflers onto the header pipes and move them around so they line up with the frame mounting holes. 

[Kenneth Pagel]

Thanks for the advice, Karl! The fact that the head pipe is supposed to go into the muffler a ways explains my problem: neither head pipe will fit in its respective muffler. I suspect that re-chroming the pipes has added just enough metal to cause this, either that or the header or muffler opening is slighly out of round. I may have to carefully grind away a bit of metal with my Dremel from either the muffler opening, or the end of the head pipe, something I hope to avoid, but may be unavoidable.

[OldSwartout]

I'd suggest using one of these. Search for a "small exhaust pipe expander".  Probably less than $20 on Amazon. You'll probably only need it for those two mufflers, so should be good.  I've used the larger versions on automotive exhausts numerous times.

[Kenneth Pagel]

Thanks again, Karl!

[disc valve]

Had just the same issue after my pipes were replated.i blued the headers up tried them in the exhaust and then disc sanded the high spots repeated till they fitted

[Kenneth Pagel]

Thanks for the suggestions, Karl and disc valve!