custom header made of stock parts

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 9:59 pm

#312748

I build my own header with parts of the stock header and catalytic converter of the Subaru EJ 22.

To gain ground clearance I cut the flanges like shown here.

[ Edited on 9-11-2005 by subaruboxer ]

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:02 pm

#312751

And got them welded like shown left here.

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:11 pm

#312759

the other parts I used : 1 x 30° bend
2 x 45° bends
3 x 90° bends
1 x tube 1 meter
all in 50 mm diameter and stainless
steel

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:16 pm

#312764

The header already wraped in thermo tec exhaust insulating wrap.

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:18 pm

#312768

Please note the cat is up side down.

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:23 pm

#312774

the header painted black, because it was shining under the car. I want a sleeper look.

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:32 pm

#312782

The mounted header before it was all finished. I am testing with 2 different mufflers, thats why there are two seen here.
I am keen to see how much power output I am going to have with it. I will get it on a dyno, but not before the end of april. It is winter here in Germany with lots of snow this year
and 3 days ago we had minus 17 degrees celsius. I have bought the stock header of an Impreza WRX STI, that will be testet too on the dyno, but without a cat. I keep you posted.

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 Mar 2005, 10:51 pm

#312790

It was to big again. I spotwelded it and went to a professional welder to get it done. I went to the welder and my car six times to get it bit by bit and a perfect fit.

[Edited on 7-3-2005 by subaruboxer]

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Jeza Officially Full-On Dubber

353 posts · joined Jan 2003 · 10 Mar 2005, 6:07 am

#314661

Subaruboxer

These updates and pics of yours are great.

Keep it up 🙂

Cheers
Jeremy

......random gibberish for today.......

lugnuts Custom Title Time!

1,070 posts · joined Aug 2002 · 10 Mar 2005, 3:29 pm

#314970

This is depressing,i feel like a junkie waiting for my next photo fix from subaruboxer,but anyway keep them coming very s l o w l y or ile OD,hey subaruboxer are u gunna put some fake exhaust tips out of the cutouts and make a SUPER SLEEPER.😉

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 11 Mar 2005, 2:57 am

#315424

Hi lugnuts, you are right the exhaust tips are put into the cutouts to have it look stock. I made a little brace for the tips, but I have no picture of it. Got to take one.

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 11 Mar 2005, 6:48 am

#315443

Found this picture of the early days. No pan, no engine but fake exhaust tips. You see, I always wanted to do it. If you can' t make it, fake it.

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 7 May 2005, 8:59 pm

#352158

mounted header

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subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 29 Jul 2005, 4:56 am

#391184

This is what it is looking like now.
The muffler is a Peugeot 206 Gti.

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boof2332 Custom Title Time!

1,210 posts · joined May 2004 · 29 Jul 2005, 7:13 am

#391191

Tidy..very tidy indeed.

How is the power and torque....has that cat actually got internals? Highly illegal here(removeing internals), although they block up and just restrict you motor after a while.

Matt

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 30 Jul 2005, 5:28 am

#391531

Hi Matt,

wasn't able to get on the dyno again with the new clutch.
The cat is the stock Subaru unit. I'd like to see pics of your exhaust.

Jörg

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 19 Sep 2005, 4:33 pm

#409487

Hi

Congratulations, that looks so nice, it looks like the factory did it, not sure which one though, the on in Germany or the one in Japan.

Steve

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 20 Sep 2005, 4:35 am

#409725

Hi Steve,

thanks I hope it will work as good as it looks. Will hit the dyno again in two weeks and the Autobahn for topspeed testing, too.

Jörg

lugnuts Custom Title Time!

1,070 posts · joined Aug 2002 · 16 Oct 2005, 8:15 pm

#418161

subaruboxer wrote:Found this picture of the early days. No pan, no engine but fake exhaust tips. You see, I always wanted to do it. If you can' t make it, fake it.

Hey subaruboxer dont forget the sleeper-look !!!!!!!!

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 17 Oct 2005, 2:32 am

#418284

Hi lugnuts,

I won't forget it. Now that I had a chance to ride, I know what I want to change over the winter. One thing is the exhaust, I will probably build a complete new one without the catalytic converter and the fake exhaust tips. I tried the smaller muffler, but it was to loud. Have another muffler that I want to try with this header, with that one I could install the fake exhaust tips.

[ Edited on 16-10-2005 by subaruboxer ]

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VWSyncroguy Learner Dubber

1 post · joined Nov 2005 · 8 Nov 2005, 8:38 pm

#426526

How is your muffler supported at the back....is it mounted tothe engine somehow ...or to the frame of the car??

Warren C.

kombibob AKA: Volkswagen Type 2 Transporter Van Robert

1,698 posts · joined May 2004 · 8 Nov 2005, 9:15 pm

#426570

sorry i just had 2

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1961 swb buggy
1960 karmann ghia
1963 Single Cab: "El Concreto"
1963 bent 23 window " Frieda Samba "
1963 Eriba Faun camper " Cara Van daCamp"
2012 Skoda Octavia scout

Get down low and go,go,go

subaruboxer Officially Full-On Dubber

292 posts · joined Jan 2005 · 9 Nov 2005, 5:47 am

#426679

VWSyncroguy wrote:How is your muffler supported at the back....is it mounted tothe engine somehow ...or to the frame of the car??

Warren C.

Hi Warren,

the muffler is hanging in those rubber things, I dont know how you call them ( in English). You can see one at the exhaust tip of the larger muffler above. And mounted to the car.

Jörg

[ Edited on 8-11-2005 by subaruboxer ]

kombibob AKA: Volkswagen Type 2 Transporter Van Robert

1,698 posts · joined May 2004 · 2 Nov 2009, 8:05 pm

#744820

Just stumbled across this while doing some subi research and had a laugh
forgot about it.. lol
so bump

1961 swb buggy
1960 karmann ghia
1963 Single Cab: "El Concreto"
1963 bent 23 window " Frieda Samba "
1963 Eriba Faun camper " Cara Van daCamp"
2012 Skoda Octavia scout

Get down low and go,go,go

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 · 4 Nov 2009, 5:33 am

#745125

that is funny!!!!

EVERLAST CONCRETE TANKS
1800 552 123

Joel Now containing 100\% E-Wang

9,368 posts · joined Feb 2006 · 4 Nov 2009, 2:34 pm

#745203

i was gonna make one similar but those stock cats are pretty restirictive

colonel mustard Son of Jim - Creator of Good

2,829 posts · joined Feb 2009 · 4 Nov 2009, 2:44 pm

#745206

How much does that heat wrap help? could you use it on extractors?? with decent effect/result?>

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 4 Nov 2009, 2:52 pm

#745213

It rusts out your exhausts alot quicker as it traps moisture. Also turns stainless brittle like glass.