S1Steve Posted December 2, 2012 Share Posted December 2, 2012 (edited) 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.. Link to comment Share on other sites More sharing options...
xcarguy Posted December 3, 2012 Share Posted December 3, 2012 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. Link to comment Share on other sites More sharing options...
MHKflyer52 Posted December 3, 2012 Share Posted December 3, 2012 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. Link to comment Share on other sites More sharing options...
S1Steve Posted December 3, 2012 Author Share Posted December 3, 2012 (edited) 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 Link to comment Share on other sites More sharing options...
S1Steve Posted December 13, 2012 Author Share Posted December 13, 2012 I have all the pieces fit up and can now start welding things up. I hope its not any louder than the old one. Link to comment Share on other sites More sharing options...
JohnK Posted December 15, 2012 Share Posted December 15, 2012 Looks great! - had any practice doing this sort of thing before? With the larger diameter muffler it'll probably be quieter. Link to comment Share on other sites More sharing options...
RGTorque Posted December 16, 2012 Share Posted December 16, 2012 make sure the muffler tip is clear of the fender or you will burn/melt/discolor your clear coat on the fender. Link to comment Share on other sites More sharing options...
Croc Posted December 16, 2012 Share Posted December 16, 2012 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: Link to comment Share on other sites More sharing options...
S1Steve Posted December 26, 2012 Author Share Posted December 26, 2012 (edited) 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 Link to comment Share on other sites More sharing options...
scannon Posted December 26, 2012 Share Posted December 26, 2012 That looks really good, how does it sound? Is it too loud? Link to comment Share on other sites More sharing options...
ihckb2 Posted December 26, 2012 Share Posted December 26, 2012 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. Link to comment Share on other sites More sharing options...
S1Steve Posted December 26, 2012 Author Share Posted December 26, 2012 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. Link to comment Share on other sites More sharing options...
coffee break Posted December 27, 2012 Share Posted December 27, 2012 The welding looks great. How did you go about doing the 4 into 1 joint? Link to comment Share on other sites More sharing options...
S1Steve Posted December 27, 2012 Author Share Posted December 27, 2012 (edited) 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 Link to comment Share on other sites More sharing options...
JohnK Posted December 27, 2012 Share Posted December 27, 2012 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. Link to comment Share on other sites More sharing options...
S1Steve Posted December 27, 2012 Author Share Posted December 27, 2012 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 Link to comment Share on other sites More sharing options...
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