haven't looked at my jeep in a couple of days, as I've been able to drive this around:

O2 sensor showed up last night, waiting on the fuel injectors, and getting paid from amazon/youtube this month so I can pick up the exhaust header. probably some time next week. We'll see when that happens.

Fuel injectors showed up! now just need to get the exhaust manifold....

Putting together play lists of all of my videos, if anybody is interested:
https://www.youtube.com/user/Jeeppat...nnel/playlists

Well last night got the new exhaust manifold on and when to put on my intake, it hits the exhaust... pushes it up about 1/4 of an inch, so it won't go into place. Do I take a torch and hammer to the exhaust to get it right, or do I go through the hassle of returning it, to maybe get another one that isn't quite right?

They make flex sections. You could have a shop cut out a straight section and weld that in. That should help with future cracking issues too as it'll allow the header metals to expand without putting strain on the exhaust mounts and such. You might also just be able to massage an exhaust mount enough to get it to line up.

is it the actual exhaust tubing or the flang that mounts flush with the head that's keep the intake manifold for going on? It seems that there are a few brands out there that don't always got 100 percent right.

Its hitting on the tube for the #6 exhaust (closest to the firewall). the flang seems just fine.

i guess try and put a little dent in it with a hammer till it clears.

I had this issue this week with my new exhaust and the 1999+ intake. Hit in the same spot and slid the intake up the 1/4 inch or so. It is a fairly common problem. I ordered mine from eBay and ended up returning it. Here is the one I replaced it with and it fit perfectly: http://www.ebay.com/itm/122018941302
And here is the original I had returned: http://www.ebay.com/itm/112053148019

The seller GalaxyPlusParts1 on eBay just had me send some pictures of it not clearing the head and he paid for return shipping and refunded me before receiving the item - which was great because I needed to buy another one.

The alternative is to take a grinding wheel to the intake and clearance the intake instead of the exhaust. Which I was apprehensive about so I figure I would return it once and then if it still didn't work I would get the grinder out. I didn't want to restrict the exhaust on the one cylinder and mess that up some how either though.

If you want it done now I'd say don't be afraid to reshape the header in that spot:

I think I'll just reshape it. I bought it from rock auto, and their returns are great, but since I'm using a stock header, there are not a lot of options for me since I have to have parts for the emissions and o2 sensor added to anything else (increase in cost.

I actually am subscribed to that channel, and watched that episode when it aired. I just need to go borrow a torch. I've been sick with a bad cold, which has keep me down pretty hard, Feeling better today, so maybe I'll get a chance to work on it this afternoon (if it is not raining)