New race header development thread

[Slouch]

Were exhaust port angles considered in this design? Also I am interested to know whether exhaust flow Radius was considered based upon the steep angles of the primaries.
The length of the tube is the main factor in where the header will perform on the powerband, so a shorter version should pick up allot more in the mid range and offer more room to play with. I understand this can result in a 0hp/tq gain on the top end which is what most people look for (stupid) instead of how much power it picks up in the mid range. Lets face it, nobody is driving around at 8500rpm all the time so power is put to much better use in the 4000-7000 range.
I think the header looks like a fine piece of craftsmanship, but a CNC mandrel bender can do all those shapes without the welds everywhere. No, I don't happen to have one either sadly...

[Bane]

Originally Posted by Slouch

Were exhaust port angles considered in this design? Also I am interested to know whether exhaust flow Radius was considered based upon the steep angles of the primaries.
The length of the tube is the main factor in where the header will perform on the powerband, so a shorter version should pick up allot more in the mid range and offer more room to play with. I understand this can result in a 0hp/tq gain on the top end which is what most people look for (stupid) instead of how much power it picks up in the mid range. Lets face it, nobody is driving around at 8500rpm all the time so power is put to much better use in the 4000-7000 range.
I think the header looks like a fine piece of craftsmanship, but a CNC mandrel bender can do all those shapes without the welds everywhere. No, I don't happen to have one either sadly...

One of the biggest constraints was the packaging issue. We had to design the header so it actually fit in the car. If you ran without a clam and cut the chassis you could make an awesome header

This was designed to give top-end power without sacrificing any low-end. The dyno I posted shows that we seemed to have achieved that goal. I am planning to do a 1500 mile follow up dyno this weekend.

[Bane]

Follow up dyno is scheduled for tomorrow at 10 am.

I think this is the first time a "vendor" is actually supplying a dyno for their parts after the computer has fully adjusted

I've been daily driving the Elise so it's had plenty of time to learn. It's gone through about 8-9 tanks of fuel and seen WOT at least 2 times a day I can't get over how it sounds. I actually went through a tunnel like 4 times yesterday on the second cam because it sounds so cool

[California Jay]

Invest in a swager ... your product will come out much better.

[Bane]

After allowing for substantial time for the computer to learn I returned to the (same) dyno today. It was much hotter (83 degrees compared to about 55 degrees last time) and we actually had to let the car cool down between runs.

Now for the news... the car made MORE POWER across the entire RPM range today. The biggest gain was in torque across the mid-range and it ended up making +1 more peak horsepower and +3 more ft lbs of torque (peak). Area under the curve increased greatly and it make +4 hp and +4 ft lbs on average across the whole curve.

I'm very happy with the results and personally think this header has been a great success. I only have the comparison dyno chart via PDF and can't seem to turn it into a picture. I can e-mail it to someone if they'd be willing to post the graph.

I ran the O2 sniffer in the tailpipe today only to find the curves had corrected to near stock levels. It was slightly leaner then stock but was flat all the way across at about 13.4 AFR. When I first put the header on, it peaked close to 15 in a few spots.

[andrewgotanelise]

congrats!

[kortik]

do you have the dyno run sheets?

[fzust]

Bane, if you have *.drf Files, i will convert to a pic for you.

[Bane]

Originally Posted by kortik

do you have the dyno run sheets?

What you're looking at is a comparison between the following:

- Lighter color = PPE header + high flow cat + Larini 0 miles and 10 minutes after install

- Darker color = PPE header + high flow cat + Larini 1700 miles and 2 months after install.

Just to say it again, the car really doesn't have 210 RWHP. It was a Mustang dyno and I think the Elise's weight was throwing it off. What's important is the relative difference.

[Randy Chase]

I can convert PDF to JPG
elisetalk at cox dot net

[Bane]

Originally Posted by Randy Chase

I can convert PDF to JPG
elisetalk at cox dot net

See above

[GTsRasta]

Nice results! You might as well go to a dynojet now for more comparable results. It's not that hard to guesstimate stock, + Exhaust, and I/E numbers before the header being added on.

[Bane]

Final results (best stock run vs. PPE run after ECU learning)



I'm very happy with the results This header offers some of the best "area under the curve" gains I've seen outside of forced induction

[shay2nak]

are you guys going to test the SC header also?

[Bane]

Originally Posted by shay2nak

are you guys going to test the SC header also?

Yes. It's in the works.

[Redliner9k]

Originally Posted by GTsRasta

Awesomeness. How close will you be following redliner9k's Lotus race header spec suggestions?

http://www.newcelica.org/forums/show...&page=17&pp=50

I would like to clarify that I was joking when I posted this specs. The specs for the Celica/Corolla/Matrix PPE header designed by me where posted.

Good gains on your header guys... am currently waiting on my own PPE header to test out in which I did some slight changes to the design and see how they work out. Already seen a 12whp gain with the regular design on the stock ecu, hopefully the slight redesign will yield even better gains.