My friend and I just got done installing the Cattman headers on my 02 Maxima. It was time consuming and we did need a few "brainstorming sessions," but overall the install went really well. The first day we had everything apart in 3 hours. I think we let that get to our heads though, because after taking some breaks, eating, a trip to the store, shootin' the $h#t with the neighbors, cutting the grass, keeping the wives happy, and of course the "brainstorming sessions," about 16 hours went by.

So let me give you some thoughts. IF YOU OWN AN '02 OR '03 OR EVEN PLAN ON DOING THIS TO YOUR OTHER YEAR MAXIMA, READ THIS!

For INSTALL CONCERNS that were resolved during the "brainstorming sessions," see below.

For RECOMMENDED TOOLS and COMMENTS/IMPRESSIONS, see the next page.

INSTALL CONCERNS:

1. My car is Cal spec exhaust but the headers only come with 2 o2 sensor ports. Solution: Take the 2 after-cat o2 sensors and relocate them behind the main cat. These are the ones in the red and white sheathing (the blue ones are the pre-cat 02 sensors).

We did have to extend the blue o2 sensors as well, just not relocate them.

We had to acquire some 18 x 1.5 mm bungs from an exhaust shop. Then weld them on the b-pipe behind the main cat but before the resonator. I recommend checking fit before taking off the b-pipe to weld (we could've left the b-pipe on the car but we would be welding on our backs: no fun). This way you know your o2 sensors aren't hitting the floor pan nor will they get KO'ed if they're too low to the ground. Put one on the driver's side and the other on the passenger's side so they'll be easy to wrench out if you need to replace them.

You'll have to extend the sensor wires. Solder them, no crimps or twist rings. The only thing to be weary about is that the factory wires from the o2 sensors don't take solder very well. You'll have to get creative with your soldering.

2. Since the '02 and '03 don't have EGR lines running to the rear header manifold, you need a plug for the EGR port. Cattman stated that in the next batch a plug would be supplied for this exact reason, but for now we'd have to make do. (I'm writing this 9/6/04) Solution: Buy a plug. Ah, but wait! A 24 x 1.5 mm steel plug is no laughing matter. No auto parts, hardware, or home supply store had anything in that size. So we broke out the sawzall and said bye-bye to that big port. We left its skinny neck though. We tapped the neck and threaded a smaller pipe plug in it. No more EGR hole. Beautiful!

3. After hand fastening the front manifold to the block, it was apparent that the stud from the front engine mount was going to be in close company. (This is the engine mount directly behind the fan and radiator.) Hmmm, any contact with that stud could scratch the coating hence rusting the headers. Solution: Break out that sawzall again! We knocked off a few threads (leave some showing for safety's sake) and the available space was comforting.

4. This wasn't so much of a problem as it is nitpicking: the included gaskets. I had some gaskets made from the same material as those supplied with the headers, but I burned through them while running nitrous. Granted, only guys who are boosted or spraying will really ever see super high EGT temps, but I don't want to go through this install again if the gaskets ever burn up. Solution: I ran down to the local Nissan dealership (whom I resolved to never do business with again after this transaction) and ordered all the OE gaskets from the headers to the cat.

I'll have picks up in the coming days.