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Stage 1.75: Header comparison blowout!

22K views 110 replies 32 participants last post by  Lurch  
#1 · (Edited)
My American Racing headers just left Calico coatings - with a little luck I might be able to get them installed this week!

The setup:

Baseline the recent build in the morning (to account for weather changes): Factory exhaust with primary cat delete (straight pipes welded in), however secondary cats and all factory pipes/mufflers remain. This dyno'd 610 RWHP about a month ago in very cold conditions with Factory blower, 10.5" lower pulley, custom LT1z cam and stock heads (15psi).

Then switch out to ARH 1 7/8 coated headers, ARH X-Pipe WITH their newer hi-flow cats into factory mufflers on the same day. Re-dyno and see what kind of power it picked up, if any. No other changes...

Note, I have a bit of a wager that with "headers only" I'll pick up at least 20 RWHP, whereas some believe the only real power gains are from removing the primary catalytic converters alone and headers are otherwise a waste of time and money.

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The Final Word:
02/20/15 baseline (with Airaid, Mamofied factory Throttle Body): 495/460

02/20/15 final numbers after cam, pulley and cat-delete: 610 / 581*
* Boost was just under 15psi, as expected.

03/19/15 "Baseline" to account for weather: : 610 / 565 (same RWHP, but ~15 less RWTQ as previous best)
03/19/15 Final numbers after ARH 1 7/8" coated headers with cats and dual 2.5" resonators into factory mufflers: 653 / 634*
* Boost was just under 14psi, as expected (around 13.8psi).
* Total Gain: no less than +40 RWHP, +50 RWTQ,using "best" runs from each session.

Dyno Graph:
Note how the powerband is actually more broad than baseline - if the peak numbers shifted higher, it's only by a few hundred RPM?

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Key: Run 08 was the 2nd baseline run (the only without belt slip). Run 11 was our best and final run of the day.

Here's the summary thread (less hypotheticals) I posted for reference in the exhaust section:
http://www.ctsvowners.com/forum/6-exhaust/26274-final-word-how-much-power-headers-worth.html
 
#4 ·
I'm curious as to the gains. I have a new set of headers and X pipe sitting here and can't decide whether to install or not. I'd be surprised if you didn't pick up at least 20 rwhp but I'm assuming that you'd have the tune adjusted for them. Without the tune I doubt you'll see much.
 
#7 ·
Cant wait to see your results Random! I have searched this multiple times and have never found any factual data. I'm betting there will be a decent gain.
 
#9 ·
Curious to see the results as well.

I know Matt keeps cam specs close, but is this more of a stage 1, 2, 2.5 cam? Even Matt's stage 1 cam's are pretty stout based on mine, so this thing is probably wanting to breathe well. I always struggle a bit with exhaust because it's not as clear cut the effects of backpressure, scavenging, etc on power. The further you get down the tube the lower the impacts of certain types of pulses and wave pressures. So it seems the largest effects will be dictated by the pipe shape and configuration closest to the heads/exhaust ports.

What I am interested to see is if there is any change in boost pressure and what, if any, correlation that has with power output. What if your headers allow better flow, with a corresponding drop in boost pressure? Since there are technically no other changes, you may not gain as much power because you aren't re-upping the boost back to the previous 15psi levels.

What if boost does NOT change but the car DOES add power? Does that tell you that you are pushing more boost that the heads and cam can make use of? Should you turn it down to save on heat created? Or does that mean you need to go bigger on the cam's intake lobe only, or do you need to increase intake AND exhaust duration/lift? This is where it can get kinda tricky!...

Then what if boost goes down AND power goes down or even stays the same? Will you blame the dyno? The weather? The other party in your little wager? I dunno. Eagerly awaiting results!
 
#11 ·
Definitely paying attention to this
 
#12 ·
Although the header horse has been beaten to death, one advantage to coated headers is the lower under hood temps. Good luck!
 
#45 ·
Stock pulleys, you can see the other mods below. It did SAE 526rwhp/508rwtq on a 91oct tune.
 
#20 ·
I've installed the headers and catted mids a couple of weeks ago along with new plugs and the cai. Tomorrow is dyno day with some road calibration thrown in. Any idea on what this will put down? I will post results tomorrow later in the day.
 
#30 ·
When you say "no other changes," do you mean no tuning changes either? You've got to keep the AFR in the same range and try to add timing to test the knock threshold to get a meaningful comparison between the two hardware setups. If your headers shed combustion heat more efficiently, you should run leaner and also be able to take more timing, so add fuel and advance timing. If you don't, then you aren't getting the full benefit of the upgrade.
 
#35 ·
Tri, I agree with you completely on the choke point. The same can be said for any orifice in the airflow path of the motor and that choke point will move around. It's the same reason why some people see massive gains with a larger intake and throttle body while others do not.

Personally when I did my stage 1 build the data that I had seen for 1 7/8 headers on cars running only an upper pulley (<600rwhp) suggested that the headers did not get you much bang for the buck. Maybe 15-20 rwhp. However, as many have posted on here you are running the risk of blowing out / melting the stock cats as you start approaching that 600 rwhp mark. Some have been fine at those levels with stock cats and some have melted them after some spirited driving. If the cats are flowing correctly that I would guess that the hp difference between test pipes and cats is minimal (again below that choke point theory). If you melt them then you are screwed and of course you will see a power difference.

It does appear from several builds on here in the range of 650rwhp+ that headers begin to net you more than 15-20 rwhp suggesting that stock manifolds start to become a choke point at those airflow values. It really just depends on the other aspects of your build.

It would be cool to see two different cars do a comparison of stock exhaust / test pipes / longtubes where one car was a ~550rwhp car and one was ~650rwhp to see the difference.
 
#36 ·
Properly sized high flow cats do not cost you much power. The problem is that in higher boost applications the heat kills them and as they deteriorate they start to cost major power and even cause engine damage.

The easier solution is to remove them if they are damaged rather then keep replacing them with new ones.

For some they will never have an issue because the car is not driven hard regularly. Others will have issues because the car is used at track events, mile events etc... My personal opinion is cats will become an issue not much past 600whp, ymmv
 
#41 ·
Good call!

I'm going to sit on the results until a case of Ruination IPA is shipped to me at no cost. You guys can take up a collection among yourselves - but I will accept $20 via paypal as a suitable substitute.

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