Thread: ZZP Headers clearance

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  1. #1 ZZP Headers clearance 
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    2005 GTP. I've installed the ZZP headers, and I have a couple of issues.

    1) the front header just barely touches the little nub on the back of the passenger side fan. Can this be shaved off?
    2) the front header also seems to barely touch the AC line from the compressor. Can this be bent easily to give some clearance? Other options?

    I've read some other posts that talk about getting slimmer fans, or removing the fan cover, but I'm not sure I really want to go that route.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  3. #2 Re: ZZP Headers clearance 
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    I don't know where its touching as I have speed daddy headers and had different clearance issues but you should be able to shave off the nub as it may have even just been there to give it more support when installing at the plant just make sure the webbing is still connected. if youre unsure send a pic of the nub and I don't know where its touching the line but maybe you can mount the canister that's under the airbox a bit lower or something and that will move the line you see the line is flexible tubing between the canister and compressor at a certain point see if you can use this in some way before bending the metal line not that it cant be done just have to be careful. but I know im lowered and have my engine pulled forward and had to remove that little metal plate for mine to fit havnt had any issues with it new headers run much cooler than the og cast iron
    2004 gtp SD headers, e85, #60 injectors, Walbroh 255lph, junkyard custom fender well intake, lq4 MAF, 2.8 Pulley, 1.95 rockers, l76 springs, ssic w/ vw rad shift kit and tranny cooler 275/45r17. BMR trailing and rear control arms, zzp STB's, tubular control arms, Dorman and Addoco sway bars, intense coilovers, all poly. avid av-20s
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  4. #3 Re: ZZP Headers clearance 
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    I will get pics of the fan clearance when I get home tonight. See link for the pic of the part of the A/C line that header is touching. It's the little canister that it's hitting, not the line itself.

    ACline.JPG - Google Drive
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  5. #4 Re: ZZP Headers clearance 
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    I got the fan and A/C line clearance issue resolved. I can at least fit a piece of paper between the headers and the fan now. Not sure if that's going to be an issue or not, but I'm sure I'll find out. My main issue now is the transmission filler tube. I can get it to go back in, but the header is in the way for it to be able to bolt back down. This has been a PIA, and I've already trashed one tube trying to bend it. I think I'm going to half to cut it, and then have someone weld it in a direction that will work. ZZP doesn't even mention this as a possible issue in 04+ GP's, nor do they even want to try and help. Did anyone else have this issue?
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  6. #5 Re: ZZP Headers clearance 
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    for my speed daddys I can 100% relate to this had to move of the house the next morning and was with my friend late that night completing the install had to bend the tube out of the way and cracked the first one. picked up a tube bender from home depot right before they closed and then had to climb a 10 foot wall into the junkyard and grab a new tube since everything was closed. seen some shadows coming our way when we left lol I always try to pay that junkyard more though because my intention wasn't to steal but it was the only way I could get the part for days. we went back home used the tube bender very carefully and got enough room to put it on and be able to fit a piece of paper thru without drag my friend didn't know a thing about cars at the time but I couldn't have done it without him haha especially the wall climbing part
    2004 gtp SD headers, e85, #60 injectors, Walbroh 255lph, junkyard custom fender well intake, lq4 MAF, 2.8 Pulley, 1.95 rockers, l76 springs, ssic w/ vw rad shift kit and tranny cooler 275/45r17. BMR trailing and rear control arms, zzp STB's, tubular control arms, Dorman and Addoco sway bars, intense coilovers, all poly. avid av-20s
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  7. #6 Re: ZZP Headers clearance 
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    I can't even begin to tell you the words that were coming out of my garage that day. Of all the things holding up a header and exhaust system install, the damn dipstick tube.... That's the frustrating part. And you can't do anything without it, because you lose more than half of the tranny fluid when you remove the thing. Does anyone know ballpark how much tranny fluid is lost when you pull the filler tube out? I bought 4 quarts, but looking at my drain pan, there's a good amount of tranny fluid in there.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  8. #7 Re: ZZP Headers clearance 
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    If you have an empty quart of something laying around, pour what is sitting in your drain pan into said quart and see how much it is. Done this quite a few times over the years.
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  9. #8 Re: ZZP Headers clearance 
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    Still trying to get the tranny dipstick tube to fit around the headers. I should've had this running a week ago, but this tranny tube has F'd everything up. I'm going to have to resort to bracketing the tube down, because the hole will never line up with the hole used when the stock manifold was in.

    ZZP mentions fan clearance for 04+, but nothing on the transmission dipstick NOT fitting at all.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  10. #9 Re: ZZP Headers clearance 
    GXP Level Member GTPpower's Avatar
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    Seems like a lot of work for 3hp.

    2001 GTP - cam, headers, nitrous, stock trans - 11.83 @ 116 <$2k in mods - sold
    2001 GTP Drag Car - XPZ, Tischler heads, NB intercooler, e85, Gen V, 2.3 w/ 5%OD
    2005 F350 6.0 - studded, deleted, bulletproofed, tuned
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  11. #10 Re: ZZP Headers clearance 
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    Well, I was hoping for 3.5 to 4 hp after the tune. I guess I should've left the stock manifold on there.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  12. #11 Re: ZZP Headers clearance 
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    It definitely would have been much easier.
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  13. #12 Re: ZZP Headers clearance 
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    Headers are a great foundation upgrade.. the benefits of them arnt seen in the headers alone. but what comes after.

    I would say if you don't plan on other upgrades then not worth the hassle.

    Plus the drop in Kr is always a plus


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  14. #13 Re: ZZP Headers clearance 
    GXP Level Member GTPpower's Avatar
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    Foundation for what? Exhaust leaks? They are poorly designed, and show no gain on the dyno. How could they possibly decrease kr when the dyno shows they change nothing? People have made 600whp on stock manifolds.
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  15. #14 Re: ZZP Headers clearance 
    GTP Level Member wowitsfast's Avatar
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    Do you run stock manifolds on your car? Not really the place for a argument about headers. He has them installed already so ya

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  16. #15 Re: ZZP Headers clearance 
    GXP Level Member GTPpower's Avatar
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    I do. My drag car also has stock manifolds.
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  17. #16 Re: ZZP Headers clearance 
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    I could've just went with the down pipe, but what's done is done. And I like the experience of doing things to the car that I've had to put off far too long. Not to mention, the exhaust was developing holes all over, and the resonator looked like someone peppered it with a shotgun.

    And it's this forum that made me decide to put the headers on in the first place. Most of the threads here say that in order to drop pulley sizes, you have to at least replace the DP, but if you can swing for headers, do it. So I did. Was it a pain in the ass, yes. And only because of a damn dipstick tube...that's what frustrated me. There were a couple of other clearance issues, but those had rather easy workarounds. And what pissed me off the most was ZZP mentions the fan clearance issue, but not the tranny filler tube. I went thru 3 tubes before I got it right.

    So hopefully, after tuning the car, then dropping pulley sizes and tuning again, I can get a little more than the 3hp that you mention. And seeing a lot of people on here do have headers, I'm guessing there are benefits to having them.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  18. #17 Re: ZZP Headers clearance 
    GXP Level Member GTPpower's Avatar
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    Sadly, we've been told that headers are needed for years. Back when they were expensive, we were told that to run faster than 13's headers are needed. When they became dirt cheap, it was one of the first mods recommended. No one bothered to actually post dyno results, or the math behind why they should work.

    Until the last few years. I used to be on the headers bandwagon, until I put a set on a new car I bought and still couldn't get it to run kr free on the stock pulley.

    If you sit down and actually do the math behind the headers available for our cars, every set is terribly designed. We have no overlap, exit angle from the head dead-ends the exhaust gas, and the primaries are not even close to long enough to promote any sort of scavenging.

    If you want to spend money and time to gain a couple horsepower while creating a maintenance headache, all the cheap bolt-ons are great. If you want to actually make some reliable power, big power, you need to fix the actual restriction.
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  19. #18 Re: ZZP Headers clearance 
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    Not looking for huge gains on this car. The experience of working on the car, and it gives me something to do besides painting the house.

    The only other thing I will do is change out the pulley to 3.6 or 3.5, and then try to tune it for around E30. The difference on my other car from the 93 pump to E30 tune was night and day difference.
    2005 GTP - Headers, 3" DP, resonator, and catback, CAI, 605 plugs *Sold*
    2016 WRX Premium - Stage 2 E30
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  20. #19 Re: ZZP Headers clearance 
    GXP Level Member GTPpower's Avatar
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    There's something that'll actually make a difference.
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