How clean does the sidewall in the header need to be? I got it smooth to where i cant feel any burs but i can see where some of the cat was attached with glue. Does all that need to come out?

 

get it clean to where you dont think there is ever a chance anything coming loose later. I used a coarse wire wheel on a drill and file to finish up with. also use an air compressor and blow out pipes really well and look inside with bright light to verify no pieces wedged in there.

 

I used a wire wheel, scraper and chisel. That glue is a bitch for sure. One thing I did not try because I did not think of it until later was a torch. If I do one again I am going to hit the glue residue with a torch and see what it does.

 

I thought about using a heat gun but i figured it wouldnt nget hot enough. I will try a torch tomorrow. I did see some shavings wedged inbetween the front pipe and the sidewall. maybe the torch will burn it out.

 

there is a little pinch point there where the front cyl pipe is. I took a coat hanger and bent it and was able to clear that area out of crap.