Thread: SD headers/plugs/t-stat/3.4/tune install w/pics

It's still in the works, I ran out of light yesterday but I wanted to add some of my progress. I'll finish up today and upload more pics as well. Installed the SD headers yesterday, didn't start until about 2pm. Just the header install is finished except I have to torque down one more band clamp and extend/install the front o2..still have to put the other parts on today. I don't have power tools or a lift so this is about as DIY as it gets. First off I think these headers are more than worth the cost, even with the added cost of some nice band clamps.


Some of the parts I'm installing. Not shown is the 180* t-stat, pulley puller, and some other things, ect..


The front manifold is really poor..now I know why they make a front log to swap this out..


Front manifold outlet and SD outlet difference, this pic does not do them justice.


Front manifold again...this thing is really BAD


(yes I know the hanger is upside-down)




Down pipes..Now here is a good reason why you shouldn't waste $100 on a 2.5" or more $$ on a 3" down pipe. This is the rear header outlet compared to the SD..Those of you who purchase just the down pipe, your still connecting it to this restrictive piece. Sure a aftermarket down pipe is better but for ~$100 more you get what I have...food for thought


The new plugs are in as well, still need to finish up the rest of the bolt-on's. The car will be up and running this afternoon. Thought? Tips, ect. I love feedback good or bad. I had to take a different car to work today.


******I have a basic tune but I'd like to get a scan for KR and further tuning. I won't have a clue how its running until I scan it. Anyone local want to help me out? I would be more than willing to throw you some cash for the tune credit and the scan. I don't feel like buying a hand-held tuner but I want to make sure the car is safe after I swap the pulley. ******* Chicago land area? I work in Antioch 60002, live in Long Grove 60047.

looks like its coming together perfectly! without any problems! KNOCK ON WOOD!

Thanks! I hope so too. It looks like the o2 sensor is going to be a tight fit. The headers weren't that hard to install though, for my first time I think it's going good so far.

Also I've read alot about the EGR leaking when people put them back on. Thats because the pipe that connects to the rear header does not fit properly in the hole..and its extremely flimsy. I've seen pics of people that had a leak and took it apart and the thing was smashed. Duh lol trim it, took me 30 seconds and it bolted up fine with a small bead of RTV for security. It's hardly off, 5 minutes with a file to the header port may get it to fit..I found that trimming the piece was the simplest way..

This is not the tube I'm talking about, it's the one that hooks up directly into the header. But in this picture you can see the extra piping that is meant to go into the hole. Trim it about 75% shorter or more..it can be done with scissors its so thin..

You are saying that you had to trim the EGR tube to get it to fit? That's interesting to me, I installed a couple sets of these and didn't run into that problem on them. I do get the EGR lined up as I'm bringing the rear header in place though and make sure it's one of the first things I do, because it can be a problem child.

On the O2, SilverGTP mentioned it on the first install and we beat the firewall edge of the tunnel to accomodate the sensor. The second one, I zip tied the o2 to the alternator bracket and sent him to an exhaust shop where a buddy put the sensor in, heated the heck out of the metal around it and angled it slightly to give it clearance. Hopefully they are making them differently and yours isn't a problem.

Yes for some reason It didn't fit right. It could of been my error or just not pushing hard enough but trimming it was the easy solution to fix it. That worries me a little that the o2 might not fit because the header is already on the car lol. I'm sure I'll figure out how to make it work, how did you fit a hammer up there?!

Should have beat the floor with a hammer to clearance the floor for the 02 sensor.

I used an air hammer.

Yeah, air hammer was used here too. However the second install was easier because the area on the header was heated and just tweaked while hot. No banging needed.

Well I did end up having to dent in the underside of the car about 1/4" to get it to clear with a normal hammer. I also added some black automotive paint on the scratched parts to help prevent rust in that area. Once the o2 was in and I could thread it, the clearance got better. It's still a little close but with the engine mounts flipped I don't think it'll be an issue. I'll have pics up soon I'm finishing up with the dipsticks and then I need to clean up! The pulley was easy.

Overall I'm happy. I'm 23 and this was defiantly a DIY job with basic tools/jack stands..if your creative and not a hot head lol. Stay tuned!

The pics I've seen on the down pipe are deceiving..it's not that low. If the car was lowered then just maybe.. I got back from a quick test drive and let the car get to full operating temp, no leaks. Sounds decent I think for what it is. I'm very happy. Tomorrow after work I'll go through every bolt and re-tighten as needed. Also take a razor to the extra RTV I used lol clean that up a bit.

I almost feel like with a good tune you could go lower on the pulley but I'm staying at this one...it's a huge improvement over before.

What pulley did you go to?

we dont need no damn EGR!

lol about the EGR I just left it on, I know it's easy to cap off. For now it's staying. In the spring when I undercoat the car maybe I'll make some other changes and take it off.

The pulley is a 3.4" On the stock pulley I saw ~5-6 psi this one is about ~10psi, ~12psi close to reline in 1st...Sound right?? I only did one short pull to test everything out. On my way to work this morning there is a small leak at the v-clamp, I didnt really put any RTV on that and it barley leaks..my fault.

What do you guys think?!

congrats for not being afraid to work on your car.

DANGIT!!! I need 200 bux... I'm so going to do this soon.... I'm tired of not having headers, just put the rebuilt engine in and didn't have enough to cover headers otherwise it would have been done while the car was on the lift.... o well it'll be a project hopefully soon before it gets too chilly.

good job, definitely jealous right now

Thanks!!

The car runs really good, I ran into 2 mustangs last night. One was a clean sliver 02ish GT, full exhaust, intake, 4:10 gear, and tuned I think. Really cool guy. Went from a 40ish roll with him about 3 cars back I heard him hit it (the thing was freaking loud as heck!!!) I stopped his pull and held it to 100. Another 50 roll we both hit it and went to 100ish. Dead even with me inching away on the top end. Then we hit a read light. He was peddling it and i put it to the floor around 10mph and it just tore em loose. He got about 1/2 out and held it. I still feel like I was inching back up on the top end. We pulled into a gas station to talk. The first thing he says is "there is NO way that car is stock" haha. It was good, he go's "I was like this GTP is right next to me, what the hell..thats a first" lol really cool guy.

Then an older Black 5.0 with with an exhaust, wheels/tires, maybe more we didn't talk. Went from a 40ish roll and pulled about a car to 100. Really cool guy as well both gave the thumbs up and went our ways.

So I'm happy..now I want more lol