I had posted serveral years ago somewhere in this thread where i bonded up the header panel bc it was cracking...
Since I had it off, here it is......
At the time, I didn't have the Saturn plastics. I had one of those crappy Taiwanese ABS header panels new in the box. The fit was terrible. So I cut it up and used the peices to bond my fenders and harden my header. its ABS, thermal expansion is different, but not that far off (better than fiberglass CTE-wise). most of my tabs were shot. I just but them out and rebuilt them.
I rebuilt the five tabs like this one. I ran a 2.5" strip down the entire length of the header to keep it together and from cracking. I don't feel like painting this car anytime soon. Marcus's carbon panels are the way to go on replacements.