DIY Header install guide?

Todd · 15th February 2007, 09:15

Does anybody have a link to a DIY guide for header install?

Thanks,

Todd

mr_bock · 15th February 2007, 15:05

I have not seen one... maybe most people just have a shop do the work. I will be starting my installation in a few weeks or so and will take pictures and if time allows, do the write up. The SS header company does not have much.

If you find something, please post.

Thanks,

gsfent · 15th February 2007, 15:44

Quote:

Originally Posted by Todd

Does anybody have a link to a DIY guide for header install?

Thanks,

Todd

No link, but from my installer, I believe entire exhaust was dropped. Let side motor mounts need to be loosened to get stock manifold off. Tough to get the SS springs on (if not SS, this won't apply). He did it over two days and it wasn't particularly difficult, but there were a couple of times it paid to have a second pair of hands.
You might check with the guys at D/A, Evosport, or Jon@Mshop.
Regards,
Jerry

shadowman · 16th February 2007, 07:41

As has been shared; rather straight forward.

The OEM exhaust is one piece as such it requires two in order to comfortably remove it.

Once out if using the OEM cats you will need to cut them at the "PROPER" place for the connecting pipes to fit well; and they fit very well if cut properly. Once cut “DO NOT” bench weld the pieces but rather install the headers; then the back half of the exhaust and then fit the connecting pipes into place last and then weld then with the assembly in place. The connecting pipe needs to be welded first around the inside tube at the cat after which the collar is slid into place and it too is welded creating the final seal. Once completed (if Tig welded) it will appear as OEM. Furthermore once the welding as described above is completed you will be done except for reinstalling the O2 sensors and misc. soft items under the gal.

Now as for removing the OEM exhaust manifolds;

The right side is NBD

However; removing the left side exhaust manifold requires removing the solo 16mm motor mount nut and then raise the left side of the motor about an inch; it is not rocket science here when up enough the manifold will slid right out. A word of caution; if you have a strut brace remove it in advance, disconnect the battery, and leave the hood open

Now once everything is out the installing of the 8 tubes can be awkward but not terrible. Once all 4 tubes on a given side are in place with the nuts snug but not tight we always slide the collector spring plate into place prior to final tightening so as to verify alignment of the tubes. Then prior to installing the collector we put some anti-seize on the tubes and within the collected and then with a piece of hardwood and a hammer simply tap it into place. Once in place the springs (likely because we have done so many are not a big deal). We have a couple bent tipped punches that fit into the slots and wholla…..

Hopefully this has helped a bit

The greatest thing I would say is “RELAX”, enjoy the process and even if you get to a point that you want to pull your hair out …don’t…..simply walk away for a few minutes and then re-approach the project knowing full well that “MANY” before you have completed it and that once completed she will breath so much better; to the tune of approximately 35 HP which you will feel from day one.

Takes care

Shadowman

code7rpd · 16th February 2007, 08:41

Great write up Shadowman. Do you happen to know what kind of horsepower increase SS headers with stock cats would provide an e39 540? Is the SS header the same for the e39 M5 and 540?

shadowman · 16th February 2007, 09:01

Quote:

Originally Posted by code7rpd

Great write up Shadowman. Do you happen to know what kind of horsepower increase SS headers with stock cats would provide an e39 540? Is the SS header the same for the e39 M5 and 540?

Thank you and you are most welcome.

Certainly I missed something however I think I hit most of the key points; however as I have always shared; if one feels like their back is against the wall by all means ask and if I see the smoke signal I will do my best to help.

The HP increase remains very similar whether using small metal bed cats or the OEM cats. Now here is the catch; a couple years ago the viability of integrating the OEM cats was sound largely because of the associated cost however as the gals have increased in miles so has the need to replace OEM cats become more common at which point I suggest folks to consider alternatives.

I will also share that all aftermarket cats are not the same even though through solicitation one is often times lead to believe that they are. Remember that I always share that "PT BARNUM" is alive and well.

Now as for the 540 and the M5 sharing the same headers; I must qualify this answer by sharing that I have never installed a set on a 540 however it remains my understanding that they are the same. Please call our to confirm this or they may in fact chime in as well.

Regardless the power to be gained as the result of headers on the 540 will also be appreciated even though a bit lower in gross numbers when compared to the M5 because the baseline HP of a 540 is lower.

I hope this helps

Regards

Shadowman

mr_bock · 16th February 2007, 12:26

Thanks Shadowman for sharing your knowledge and tips!!!!!! This is exactly the kind of stuff that only comes from experience that will help alot.

Very much appreciated!!!!!!!!!!!!!!!!!!!!!!!

Gustav · 16th February 2007, 12:38

Very true. Have a look at my Supersprint report here:

My Supersprint factory visit via Monaco and Ferrari: a 6000 km trip (4000 miles)

Superspritn and it's springs makes it possible to install the system without moving the engine: with other systems that migh tbe possible. Installation ivolves removing the steerring comumn and more, at Supersprit faciltiies it took over one day.

Quote:

Originally Posted by shadowman

and that once completed she will breath so much better; to the tune of approximately 35 HP which you will feel from day one.

Takes care

Shadowman

whatheheck · 16th February 2007, 12:59

Excellent write up Mr. Shadowman. Thank you!

FYI, I am having my SuperSprint headers and connecting pipes installed right now by an installer. He doesnt have any experience on this yet so it is taking him a little time.

According to him, my stock headers are out and the SS headers are already in. He said the stock headers were a pain to remove.

He is a little puzzled on how to properly install the connecting pipes though. Your input should help him a lot so I will forward the info to him as he expects to finish the install job today.

Jon@mShop helped me out too. Lots of very helpful people on this board.

Many thanks again for sharing all the info. I will take photos of finished installation and share it with all of you.

I expect to get my beast back tomorrow, then reload Powerchip 93.

I cant wait to hear the better sound the SS will add to my Tubi Rumore Plus exhaust, and feel the butt o meter improvement.

Quote:

Originally Posted by shadowman

As has been shared; rather straight forward.

Take care

Shadowman

Jon@TheMShop · 16th February 2007, 17:37

Quote:

Originally Posted by code7rpd

Great write up Shadowman. Do you happen to know what kind of horsepower increase SS headers with stock cats would provide an e39 540? Is the SS header the same for the e39 M5 and 540?

Not sure how much the power gain will be on the 540i (maybe more than 25hp) but the Supersprint Headers are the same for the M5 and 540i. It is highly recommended to get software though. Contact Shadowman if he has software available for the E39 540i header setup.