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I did the drilling and tapping with the engine running. Then stopped the engine, antisiezed the fitting and screwed it in there. It just needs to be snug. There really isn't much pressure in this exhaust system. This is soft metal, so if you crank on it, you will strip the threads you just created. My engine was up to operating temp when I was doing this.

As far as temps, pre turbo (a la hoot), the max safe sustained is 1250 degrees. You can go over that, but don't do it for very long. I have seen 1300-1350 pulling a grade and down shifted to get the EGT's back down. A 4" exhaust system is in my future, but the 2nd fuel filter took priority as the tow season is almost over for me.

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