TOPIC:

I have a mystery header that I believe to be a Mac. My issue is the flanges on the headers are captured and non removeable but go so far down the stud that I couldn't put a nut on tight if I wanted.

I can see from the corrosion on the headers some sort of spacer was once used?

Suggestions?

I can't really picture what might have been there before, but it seems like a stack of plain washers on each stud would take up the gap.

Exhaust gaskets installed in the head?

Not the best fix but you could double up the gaskets and add ultra copper between them. I like DOHC’s suggestion also. 

Exhaust gaskets are installed. Making small sleeves/spacers was what I was considering but thought there must have been a better way haha. 2pc collars overt the top of something.

My local hardware store has an assortment of steel and aluminum spacers that you can buy.  They come in different widths and diameters so you might find something that will work and look good too without going thru the chore of making them or stacking washers.

Rick H.

Suitable sized studs?   

The wear marks on the pipe make me think that there are some missing split collars.

Here is a discussion thread with pictures.

www.kzrider.com/forum/2-engine/593029-ex...tion?start=12#624929

The MAC I have, has the collars welded on. That's why the flange can't be removed.  So they can't be missing, otherwise the flange would come off.

It's strange indeed.  Maybe the header is from some other bike, like a Suzuki GS or something?  I thought I recall they have a similar cylinder spacing from the Kz.

The Kz1000 flange is indeed pretty deep.  Great Post by Patton: 
www.kzrider.com/forum/2-engine/517233-78...aust-question#517244

From the pic you posted it would appear that the stock split collars and stock flange were placed outside the welded flange on the pipe to take up the space.  Shorter studs, a stack of washers or a tube of correct ID, OD and length would be the quickest fix if you do not have the stock split collars and stock flange. 

The OP said the flanges are not welded, but are captured, so split collars should work just fine.

Maybe I am confusing myself with terminology. The flange I am referring to Kawasaki calls the exhaust pipe holder. It fits over the threaded studs and transfers the pressure from the nut to the pipe, via a sleeve welded onto the pipe.. However, in re-looking at the picture, if the pipe holder was as far out as the wear marks, the studs would be too short to reach it. Some pretty short split collars would be needed, or some spacers as discussed above.

I believe these were for the earlier year kz1000s, possible changes to depth of exhaust pocket for J motors?

anyway. Here is the fix for now.