Header installation update>>

[Dave C. '04 Z06]

I just started tonight to install the Hooker Super Comp headers to replace the cracked exhaust manifold.

I ordered part # HOK-2061 from Summit Racing (paid $328 after tax) and first of all I'd like to say that the headers look really nice. They have the AIR tube hookups and the welds are nice and smooth. I got the black painted ones and the finish is nice also.

I spent two hours working on it tonight and I have both manifolds with two bolts left holding them in. I will raise the car tomorrow and undo the cats from the manifold collectors and then remove them. When I removed the spark plugs they looked like the original ones (130K miles!), the center electrodes being worn down pretty bad.

All I can say at this point is it is a heck of a lot easier to get the manifolds off a Corvette than it is a Camaro.

The drivers side I had to unbolt the AC compressor to get a bolt which stabilizes the accessory bracket, that's hidden between it and the accessory bracket. I also had to remove the ASR modulator. On the passenger side the biggest thing you have to remove is the metal AIR tubes and oil dipstick tube. Also, the wire loom holders on both sides have to come off.

I will give more details tomorrow when I hopefully finish.

-Dave C.

 

[Ken]

Thanks for the information Dave. Glad to hear that things go as planned sometimes.

You're gonna love the performance with new plugs if they are as bad as you describe. That, combined with the new headers, man, you're gonna think you have a new engine!

_ken

 

[Dave C. '04 Z06]

Finished >>

Update for my 1995 Corvette header install.

The Headers are the Hooker Super Competition shorty's designed to bolt to the stock exhaust system. (replace the manifolds basically) I paid ~$330 from Summit Racing for them.

Well, the header install took longer than expected due to a number of reasons.

First of all I had to dimple the tubes around where the bolts are because there wasn't enough space to get a wrench on the bolts (you would think header companies would do this for you since it ALWAYS has to be done). Also, I had to grind the lips off the factory studs (for the brackets and oil dipstick) because there was not enough clearance for them and I didn't want to dimple the headers that much.

After I got them on then I realized that the EGR tube (which is metal) was now too long because the factory manifolds have the EGR connection between the two middle runners and one the headers it is on the #6 pipe. So I had to cut about a 1/2" to 1" out of the metal line and then weld it. I was worried about using rubber tubing because of the hot exhaust gas. On the drivers side it fit because they already use rubber over there because it is after the check valve, but since the passenger side is dual purpose (EGR and AIR, depending on the flow direction) I was afraid it would melt the rubber.

Then, over on the passenger side I found that the brackets that bolt to the exhaust studs (to support the AC and accessory bracket) didn't fit on the stud due to the clearance of the header tubes. So I had to cut the tips off the bracket rods and now they fit.

The headers themselves actually fit really nicely in there, however.

But the car feels alot stronger now above about 4500RPM. So that's good. And it's certainly quieter now which is the important thing! The factory passenger side manifold turned out to have 2 NASTY cracks in it!

After inspecting my passenger side exhaust manifold, I found that the port for #2 was basically cracked all the way off (right after the bend going toward the collector). The only thing holding it together was the iron bar that runs between all the ports along where the gasket is. It was also 75% cracked at the same point off the #8 port.

The drivers side manifold was fine.

Another interesting note: On the cast iron LT-1 manifolds (at least for a 1995 anyways) the two center exhaust ports share a common runner. So basically there is one big runner for the center two ports, and of course seperate ones for the outside ports. This seems to be very detrimental to performance. It's interesting that the on the Camaro cast LT-1 manifold, there is an individual runner for each port, even the two center ones. Maybe because it was designed after the 'vette one or something. But that right there is probably a major contributor to why it seems to have improved the performance.

Oh well, talk to you guys later.. I have to start sanding my Camaro's hood (for the 3rd time...)

-Dave C.

 

[Dave C. '04 Z06]

oh yea, because I used copper gaskets, I have a small leak on the driver's side. I'll have to tighten the bolts some more to crush it properly. But ther than that, it's been great for the last two days.

-Dave C.

 

[Gorgon]

Sounds great. My concern is the amount of modification you had to do to get the headers to fit properly. Why aren't these a better fit? Is it because of the price?

Leon

 

[Dave C. '04 Z06]

The headers actually fit really nicely in there. It's just things like the bracket reinforcement bars couldn't go onto the studs because of where the holes were drilled in the tabs of them. I imagine some people could get lucky and the holes would be drilled far enough along the tab that they could clear.

But if you've ever installed any headers before, you'll know that there is always something that has to be "finessed".

And the one good thing is that the collectors aligned well with the factory exhaust pipes, and the bolt holes were drilled right on the money for the head mounting.

-Dave C.