Headers question on 2004+

**comatoast** · 06-27-2013

Just wondering what are the issues with headers on these cars.. Is it the Oil or trans dipstick that needs to be bent, and are there any clerance/fitment issues with the front hitting the radiator fan shroud? Im looking at the ZZP stainless and the SD.. Not sure what way Im gonna wanna go yet, but im guessing they will have about the same performance, but will mostly come down to quality.. I live in MN so we have some nasty winters and heavily salted roads, but not sure If Im willing to pay 4 times the price, especially if its the same performance

**REDCRAPGP** · 06-27-2013

When I installed my SD. I removed the metal fan shroud. Bent the AC line just a bit for bit more clearance. I didn't have to bend the oil or trans sticks. Went ahead and flipped my sway bar for a bit more clearance and that's it. Some guys have to slightly bash in there firewall to give the upper O2 a bit more room but I didn't have this issue.

ZZP headers will flow better obviously but unless your going for all out power SD's would do the job for a fraction of the cost.

**comatoast** · 06-27-2013

so with the SD's what else would I need? Good clamps, possible an O-ring for the dipsticks if I need to take them out /or bend them, an o2 extension.. anything else?

**REDCRAPGP** · 06-27-2013

Good clamps. Replacing the flex with a ZZP flex pipe is recommended since the one that comes on them tends to go out real quick. O2 extension...but I ended up just making my own. You can either keep the test pipe or weld or clamp in a catalytic converter but remember 04s would need the codes deleted if you decided not to run one. I used the spark plug fouler trick myself but will be getting a magnaflow cat soon.

**comatoast** · 06-28-2013

Originally Posted by REDCOMPG

Good clamps. Replacing the flex with a ZZP flex pipe is recommended since the one that comes on them tends to go out real quick. O2 extension...but I ended up just making my own. You can either keep the test pipe or weld or clamp in a catalytic converter but remember 04s would need the codes deleted if you decided not to run one. I used the spark plug fouler trick myself but will be getting a magnaflow cat soon.

thanks man! I recall seeing somewhere NAPA has good band clamps..?? 2- 2.25" and 2- 3" correct? will any flex do, like a good one from a parts store or exhaust shop, or should I just go thru ZZP? Ill check out zzp now, as Im assuming they will have the o2 extension as well? also, will I need any new donuts, or rtv for the seams?

I will eventually be getting an overkill pcm once I know for sure what my mods will be, so I will just have him delete the rear o2..

Also I might need a new flange, because I cut the resonator out, and the flange that bolts the rear section to the DP

**REDCRAPGP** · 06-28-2013

Yes 2 2.25 and 2 3" once. Napa has the best clamps or you could order the band clamps from FrozenBoost.com if you don't mind having them shipped. ZZP has the extension you need but you can save yourself some money and extend your stock o2 yourself. I would stick with a ZZP flex since I have yet to hear anyone having any issues with them going out. Copper rtv is optional. As long as your stock gaskets are in good shape. Clean them up and reuse them or you can get some Felpros. I also replaced my exhaust donuts since I was missing one. For the gaskets they should be in stock at the local parts store if worse came to worse and you needed to replace them.

**comatoast** · 06-28-2013

So heres what I have so far

this Im assuming will be option "C" since I have a 2006
Easy Performance - O2 Extension Harness #EP-O2EXHN

2- 2.25" , 2- 3" of these
ZZPerformance - Stainless Exhaust Clamps #ZZ-SECLMP

This flex, what size is the one on the SD's? 3"? Im assuming just sawzall off at the weld, then weld the new one on
ZZPerformance - Interlock Flex Section #ZZ-FLEX

any studs, or anything else you can think of?

**REDCRAPGP** · 06-28-2013

Correct.

Clean up and reuse your stock gasket. The ones that come with the SD are garbage.

You'll also will reuse the stock manifolds studs and bolts.

**REDCRAPGP** · 06-28-2013

Optional...copper rtv. Exhaust donuts. This things you can get locally if you decided to use them.

Then of course decide what you want to do about the catalytic converter.

**comatoast** · 06-28-2013

sounds good, thanks for the help man, just wanted to get a heads up of everything Ill need so Im not missing anything.. How many donuts are there, and will Napa do for those>? One of mine is leaking anyways.. Im getting ticking under almost all acceleration ad its annoying as ****

**comatoast** · 06-28-2013

I wont have a cat, as we dont have emission testing here.. So whenever I get all my mods done Ill let Will know what I need, then order the PCM

**REDCRAPGP** · 06-28-2013

2 donuts. Napa should have them. I think I got the Walker brand from Advance.

**comatoast** · 06-28-2013

Other than that, is there any sort of heat wrap to protect o2, plug wires or a/c line from heat?

**Timing** · 06-28-2013

Things i did when i installed mine were take fof rad fan metal cover thing, bent ac line underneath it, bend trans dipstick, and dropped craddle 2 inches to get the rear header in. But as far as the flex goes cut that one off then weld in the new one and have them weld in a better downpipe that doesnt dip low and flows straighter.

The rear o2 wire goes underneath the heatshield

**comatoast** · 06-28-2013

Anyone have any pics lol? Of the fan shroud or how its all routed? So basically everything from the flex down needs replacing on the SD headers

**dsmuts** · 06-28-2013

I removed the small metal heat shield. Dented the firewall to clear the o2. I used the sd flex for the last 2 years with no problem. With sd you don't need donut gaskets

**comatoast** · 06-28-2013

I plan on taking this thing to the track for the first time next month and would love to have everything in by then ( headers , intake , 3.6, overkill pcm ) the track has some 110 so Im not worried about knock there, but is 93 enough to keep the knock away on the street as a DD? I had a 2000 ssei with the intense level 1 kit , no headers , no cat, no res, and a 3.4 pulley, which seems to be the same as a 3.6 on a gen V, and I got KR all the time..

**Timing** · 06-28-2013

Originally Posted by comatoast

I plan on taking this thing to the track for the first time next month and would love to have everything in by then ( headers , intake , 3.6, overkill pcm ) the track has some 110 so Im not worried about knock there, but is 93 enough to keep the knock away on the street as a DD? I had a 2000 ssei with the intense level 1 kit , no headers , no cat, no res, and a 3.4 pulley, which seems to be the same as a 3.6 on a gen V, and I got KR all the time..

It all comes down to the tune. A overkill tune is great as a base tune but def get a street tune from someone in your area. I had kr untill i tuned mine and i had header intake and no pulley drop.

**comatoast** · 06-28-2013

Originally Posted by Ginseng

It all comes down to the tune. A overkill tune is great as a base tune but def get a street tune from someone in your area. I had kr untill i tuned mine and i had header intake and no pulley drop.

Yea, thats what Im worried about.. Man they really lock you into a 3.4+ until you do alot of ****.... at this rate, it seems you would need a Full I/C rockers, springs and head work to even run a 3.0

If there was anone within 100-200 miles of me.... Id get one... afaik, NOBODY around here has HPTuners, none the less much knowledge about the car in general.. If it was a SRT or a DSM, I would be set..... but no chance w the GP