Troublesome exhaust

[Steve]

Wooders,

From memory the cost was about $550 for the header only. Plus the same again in labour seeing how they have to remove the entire fuel injection system to put it on. There was someone on here or EJ at one point in time that had them. Can't remember. [img]graemlins/dunno.gif[/img]

[oscar_the_grouch]

Steve n wooders i think gojeep has the hi tech headers on his xj [img]graemlins/dunno.gif[/img] ...i think i saw his write up on his site

[merolius]

i have the same problem with my header cracked at the collection point , discovered when cat destroyed it self .tried fixing in car but made it worse . sounds like a truck now. so you have to remove efi grrr at that job .

[Kramer]

Yep, this is a common problem with the Stainless factory headers.

My 96 XJ was doing it when I bought it at 174k and I had it fixed at that time before paying the cash. You can't successfully repair this in the car, manifold off job for sure. You have to heat the manifold to a high temperature and keep it VERY hot whilst welding - bit of a specialist job. Take the manifold off and turn up at your local exhaust bloke at 5 pm one day with a nice bottle of Scotch [img]smile.gif[/img]

The manifolds are not hard to take off, but you will need time. As in allow 3 hours to get them off (use a manual if it's your first time) and probably 2 hours to put it back together again (use a new gasket, they don't cost much). There is really nothing to the job - you just need a tool kit with various lengths of ratchet extentions to get to those manifold bolts. Have a go if you're confident. [img]graemlins/dunno.gif[/img]

It will probably start cracking again right next to the weld in due course, but that's the problem with stainless. Extractors will affect insurance as well in most cases, so check with your insurance mob first...

"Gojeep" ditched his factory headers at 100k - read his writeup on his website it's called "Exhaust for Torque". He's very approachable but in Tassie at the moment touring for a couple more weeks.

Kramer

[Wooders]

Well after talking to HiTech I'm ruling them off my list.
They quoted me $2500 for the full system (inc headers) but that's only in mild steel...Stainless was another $200...$2700 is over double other quotes I got....

Just for reference: (First mild steel & second Stainless)
HiTech - $2500 & $2700 2¼" pipe. Wanted me to supply the gasket too.
Tuffy - $1600 & $1900 2¼" pipe. Custom built headers & tubing.
Midas - $1750 Mild only. Didn't think they was Stainless available [img]graemlins/crazy.gif[/img] Didn't bother to ask about the tube size etc.
QuickFit - $1450 Mild only. 2¼" "sports" system.
Hornsby Mufflers - $850 mild only. 2½" But retains the stock cat....

hmmm decisions decisions [img]tongue.gif[/img]

[ 08 January 2003, 03:09 PM: Message edited by: Wooders ]

[hoppy]

what happens if the cat is removed altogher
is it legal ?
any other parts need to be removed ?
performance worse or better
hoppy

[Kramer]

Removing the cat is not legal - EPA will send a pole up said arse if caught.

Use a hiflo cat. Minimum is a cat and one muffler. I ended up replacing the exhaust system with a 2 1/4 system, sports, hi flo everything. Initially I went without the resonator but ended up putting it in for drone reduction. $550 all up (not changing any pipework, that's just for the cat, muffler and resonator installed).

The car sounds great, and has heaps of go.

BTW the guy I went to is in Melbourne on Dandenong Road, near the Darling Road intersection in Carnegie, opposite Radio parts - drop in and see Domenic there if you're interested Melbourne boys.

Kramer

[ 08 January 2003, 05:02 PM: Message edited by: Kramer ]