Berk HFCS Install tomorrow.. Need input.
 

Greetings,
If you could read from the title already, I'm tackeling my HfC install and had a few questions. I know people have trouble getting to the cat to header bolts but I'm worried about how hard these "Demon bolts" are to really get off. I understand those are really the only thing that makes this install challenging. I know I'm going to have to take some of the intake tubing out to get to the bolts. Would my best bet be to get some bolt breaker etc to help free the bolts and make it easier. Also from experience how many of you broke tools trying to accomplish this task? I have a car lift to save me from the fear of being crushed.

Thanks for any and all comments!

I was able to swap both mine out in about two hours. Socket extensions are your best friends

I have some extra long extension from a buddy that is a diesel mechanic so I think I'll make it and he might help to make the process faster. Were the bolts ungodly hard to get off or a breaker bar will do the Job?

I sprayed all bolts with liquid wrench for two days then hit it with a 18" breaker bar. Came off pretty easily after that.

I'm gonna go in dry! Opinions on what I break first?

I started on the bolts that are accessible from the top once intake tubes are removed

And then finished with the Cat support bar, O2 sensors, and Y-Pipe bolts?

Took me 6 hours but I took my time, no striped bolts or broken wrenches. I recommend pb blaster 2 hours prior. Two demon bolts were a pain and you need an extension with breaker bar. Good luck its well worth it taking your time and sounds amazing.

Blast the heck out of b them with lube. Might even want to start the engine after to let things expand and work some lube in. Have a 1/2 wobble bit handy! Get a extra bar to add on the breaker bar. Put the sockets in all the way till it can't go anymore. You want as much contact as you can. My cats are on good but u got them out in about 40 minutes. However, I didn't have a transmission in the way either. The cat bolts were in easy reach and I pulled as hard with I could to get them off. I think in my build thread, I have a picture of the tools I used and some of the broken bolts.

I just checked my build thread. The picture is on page 8.
YzGyz

PB Blaster is $3 from Advance (worth every penny)
Top engine brace is easy to remove and can make life easier
Don't use a swivel for the top header bolt on the outside driver corner
Ratchet wrenches get to the tougher spots for install
I used the wheel lug wrench to get extra leverage (only use if you're poor and can't afford a breaker bar) :)
High impact sockets wont strip your bolts as badly

Took me 3 hours...had to use an 18" extension from the top to get to the bolts and I was lucky that the 2 hardest ones broke. Use a lot of PB Blaster, take your time.

You will be rewarded with the sweetest sound...

Well I finally finished the install. Stripped a bolt on the Cat support bar but just torched it out but damn did my buddies and I almost give up. Broke two extensions, then decided to get the thicker metal extension and finally broke two of the bolts off.. Finished her up and love the better sound. You can definitely hear the difference!