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  #481  
Old 01-26-2013, 05:15 AM
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Re: Grand Willys project


My headers arrived from the US in only 5 days, which is pretty good going! They cost me $549 USD, ($523 AUD), plus $200 USD, ($190 AUD), for the freight. They are the OBX ones which look like a copy of the Kooks design.


Here is what the factory cast manifold looks like.


Talk about a difference!
The headers are made from 304 polished stainless steel and run 1 7/8" primaries and 3" collectors. Nice 3/8" thick stainless steel flanges too.


Big difference in outlet size!
Was surprised to see a transition spear on such a cheap header too!


Here is the main difference between the 05-08 5.7 Hemi and the 6.1 SRT8. The SRT8 has D shaped port verses the square of the 5.7. From 09+ with the VVT, they 5.7 and the 6.1 share the same port shape. Strangely, most 5.7 headers are sold with round ports so don't match up well anyway!


Good thing about the port shape difference is that the D shape equals the height of the 5.7 and there is nothing in the way to impede flow.


Close up of port shape difference. There will be no trouble with the flow coming from the smaller square port into the larger D shaped ones of the header.
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  #482  
Old 01-26-2013, 07:53 PM
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Re: Grand Willys project

Verrry nice!
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  #483  
Old 01-26-2013, 08:01 PM
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Re: Grand Willys project

What is that black tube coming out the back? Some sort of rear protection?

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For colour I am looking at a bronze with a pearl in it. Prefer to use a Jeep version if I find some thing that grabs me like the latest compass.



2013 Jeep Compass Specs, Review, and Pictures 2013 Jeep Compass pictures

Called copperhead pearl. There were some Wrangler shades in the bronze too that were quite good. Trouble I have is over here is finding one in the flesh to look at in different lighting conditions as not many Jeeps sold here.

For wheels I will most likely run a Smoothy with an original Jeepster cap in the middle.
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  #484  
Old 01-26-2013, 08:14 PM
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Re: Grand Willys project

Rear bumper guard
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  #485  
Old 01-27-2013, 03:32 AM
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Re: Grand Willys project


Had 10 minutes to spare so quickly threw on one header. Cannot use the stock bolts so either use the SRT8 ones or some M8x30mm with 1.25 pitch flange head bolts. I just picked up some zinc plated one from the local auto parts store. Might switch the stainless ones for finial assembly.


Plenty of clearance to the starter and nothing interfered at all.


I'm pleased with the way they look.
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  #486  
Old 01-27-2013, 07:55 AM
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Re: Grand Willys project

That looks sweet Marcus! I know it's on the other side but hows the steering shaft clearance looking?
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  #487  
Old 01-28-2013, 06:07 AM
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Re: Grand Willys project

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That looks sweet Marcus! I know it's on the other side but hows the steering shaft clearance looking?
Last night I got the other side in as well, pics coming soon, and clearance seems to be alright at this stage. Can't really tell until I have the firewall in place though.
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  #488  
Old 01-28-2013, 07:14 AM
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Re: Grand Willys project


On the right front cylinder head at number 2, there is the EGR port on the 5.7 which is not on the 6.1. It comes out just if front of the exhaust port in the head and then enters the manifold where it makes a sharp 90* turn into the exhaust runner.


Some people just use the 6.1 gasket and leave it blocked off, but you will get a code showing low EGR flow. Also it runs a little cooler they say with it running so I will make sure it is. I placed the stock gasket over the flange so I could mark out where the extra flange bolts needs to be drilled as well as the position of the EGR port.


The extra flange hole needs to be drilled 11 mm like the others in the flange apart from the slotted one shown. A slot needs to be made from the bigger circle so the EGR can flow into the exhaust primary.


The flange is 3/8" thick so used a die grinder to make a slot just over 3/16" deep


I also cut the gasket to give more area for the gas to flow into the primary as it would no longer act to help seal anyway with the gas running on one side of it and would burn some of it away over time. For final assembly I will use a 2009 5.7 OEM gasket, don't use any thing but OEM, as it has the D shaped ports and the EGR hole and slot already punch in.


A good thing about these headers is that all the lower bolt holes are slotted so I just screwed in the bolts part of the way through the gasket. This helps keep it in place and the header was slipped over the bolts and the rest of the bolts screwed in with my fingers. Having a stand to support the other end of the headers makes it easier too when doing it by yourself.


Can see how the EGR port sits in the head. Very tempted to die grind a slot on this side too, but others have reported it works fine without doing that when using the 6.1 stock manifolds on these. Be very easy to just drill through the port into the EGR port, but don't know where the oil and coolant passageways are and hate to drill through one!


The extra forward hole can be seen here that the 6.1 doesn't have. So remember to take that into account when buying your replacement M8x30x1.25 bolts. You will need a total of 17.


I was happy to see that these headers cleared the bell-housing just fine. When you run the 6.1 stock manifolds on these, the bolt hole protrusion shown here needs to be cut off.


Another side done.

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  #489  
Old 01-28-2013, 11:47 AM
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Re: Grand Willys project

Very Nice! What type of exhaust are you going to be running?
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  #490  
Old 01-28-2013, 04:59 PM
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Re: Grand Willys project

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Very Nice! What type of exhaust are you going to be running?
Mopar/Corsa one as only one I can find that does not drone when running long tube headers. They might arrive late this week if all goes well. Fedex tracking number says it has already been delivered to some one in the US though!!!
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  #491  
Old 01-28-2013, 06:12 PM
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Re: Grand Willys project

Oh no! Thats weird
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  #492  
Old 01-28-2013, 06:40 PM
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Re: Grand Willys project

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Fedex tracking number says it has already been delivered to some one in the US though!!!
Uh.... yeah.....about that ...um...thanks Marcus!
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