Fitting the new header and muffler

[S1Steve]

I bought a new Caterham SV header, and a new R 300 muffler and thought I show how

 

its is working out. The header fits great. To get it thru the side of the body I did some

 

sheet metal work. ( I always said I would never do any body mods, Yea right..)

 

One remaining piece is a slip on collector or a flange to match the header, and a o2

 

outlet.

 

Where is the best place in the system for the O2 outlet.

 

Steve

Edited December 2, 2012 by S1Steve
sorry for the crappy photos..

[xcarguy]

Steve,

 

Nice car. Where was the previous location of the O2 sensor? As it stands, I'd say place it (the O2 sensor) in the top of the collector, just aft of the header.

[MHKflyer52]

Hi Steve,

 

You might want to put the O2 Sensor bung on the inside of the collector next to the body as this will help protect the sensor and the line to it. You also want to make sure the sensor bung is in the area that has full exhaust flow from all the header pipes so that it reads the total exhaust flow and not just one cylinder.

Here is a JPEG of a 3D-Model of a four into one collector with bung to show you an example.

Hope this helps.

[S1Steve]

Thanks for the replys. The 02 bung will move away from the head by two feet. I posted a photo of the old header. From what I read there will be no affect by the extra length.

Martin thats were I planned on putting it, only because that looked like the best place to weld it, and as you said it will be out of the way. So it seems like I am on the right track. Ask first, drill and weld second..

 

Thanks for the help, Steve

Edited December 3, 2012 by S1Steve

[S1Steve]

I have all the pieces fit up and can now start welding things up. I hope its not any louder than the old one.

[JohnK]

Looks great! - had any practice doing this sort of thing before?

With the larger diameter muffler it'll probably be quieter.

[RGTorque]

make sure the muffler tip is clear of the fender or you will burn/melt/discolor your clear coat on the fender.

[Croc]

make sure that you never park an orange pearl car over gray carpet in the future - it really just does not look good!

 

Would you like any other helpful suggestions? :jester::seeya:

[S1Steve]

I'm going to call this little project done. Thanks to those that provided the parts and advice.

Sorry the gray carpet is in the pictures.LOL Next job is doing some engine work.

I'm still working out the details, but looks like some head work, cams, and then on to the dyno.

My new best pals at PSI performance in Lansdale Pa. are going keep the webcon setup, their tuner says its not the piece of shit I think it is..... Just want to be able to keep up with the MONSTER Caterham's at the up coming LOG....

 

And its not as loud ... No test drive because its snowing....

Edited December 26, 2012 by S1Steve

[scannon]

That looks really good, how does it sound? Is it too loud?

[ihckb2]

I've got the same muffler and plan on building a new header this winter. Interested on how you mounted the muffler. Can you post some detail pictures to show how you did it. I had a circular band built to hold the muffler and hang off the side of the car but it looks a little ugly.

[S1Steve]

Skip, Sounds alot tamer than the old one, and no rattles. We had some snow today, so

it never left the garage. Thanks for your help !!!!

 

IHCKB2, I used the same mounting tab on the S1, which did not match up with the muffler. So I cut the hanger off the muffler( it was at the tailpipe), and moved it onto the body of the muffer.I will be happy to take photo's of what I did and post them for you.I also found a good place for collectors and pipe,02 bungs if you need parts.

[coffee break]

The welding looks great. How did you go about doing the 4 into 1 joint?

[S1Steve]

Cone Engineering and Megs Engineering sell what is called a Swege Formed Collector. So I welded the travel piece with the angle to the collector ( Post # 5), and then put a tiger paw on my grinder and knocked down the weld flush. Then I polished it. So there's no weld showing, looks nice and clean I did the same on the 4 into 1.

Edited December 27, 2012 by S1Steve

[JohnK]

Let me know if your new tuners would like the Webcon CD, or anything else I might be able to scare up. Best of luck here-passing things on to the next generation.

[S1Steve]

Let me know if your new tuners would like the Webcon CD, or anything else I might be able to scare up. Best of luck here-passing things on to the next generation.

 

Hi John, I'll take you up on that offer. This tuner had great answers to my questions, and he showed me how he is going to tune it real time and then burn then burn the eprom.

This guy is a programer by trade and seems to really know his craft.

Lets pass the buck, and see how it goes. I think you have my address ??

 

Happy New Friend, Steve