626 4-2-1 Header install problems

Jeezus

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2002 Mazda Protege, 2002 Mazda Miata, 1982 Mazda RX7
Got my 4-2-1 installed. I have a major rattle between 2-2.5k rpms. Not much of a rattle as it sounds like it is vibrating against something rather strongly. Thought it would be my 2nd O2 sensor, so I removed and plugged it (it almost sat on the transmission). Still got the rattle, so I thought it would be hitting the under brace between the lower suspension arms. I bent the very end of it down and now have about a half inch of clearance. Still gets the noise.

Thing is, when I first start the car, no noise. I can pull out of the driveway from first to second, no noise. Pull on the street, no noise from first to fourth, then by fifth it begins. After it rattles, it will rattle in any gear. This is extremely annoying as most speed limits here are 45, which is right at the rattle point in 5th.

I am thinking it might be where the header collects into the dual pipe, as those studs might have somehow worked their way loose a little bit? I will weld the top of them to the flange. Other than that I am stumped.

Has anyone installed this on their protege and had this problem?
 
I had them on before. The way that flange is between the two pipes (3 bolt) I always had problems with those bolts. Make sure you buy extra gaskets for those.

Do you have any pictures installed?
 
Extra gaskets for the 3 bolt flanges? I believe someone told me they were accord gaskets, I will look for them.

Did you have the rattle issue? I believe it is where the 3 bolts hook up.
 
Ok, thank you. I will remove the gasket that came with it and double gasket it with ones from an accord.

I plan on just tack welding the top, don't care if I can see it :)

Will post pictures this weekend.
 
Hey...off-topic, I know, but...where'd you get your headers, and what diff did they make?
 
Ebay 626 headers. Not sure on the difference, I usually shift by 3k before the headers. If I knew it would be this much trouble I would have stayed stock, it sounds nicer. I also believe the headers collect incorrectly per the timing order.
 
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