Jay (Choi0706) asked me to post here regarding my header (exhaust manifold) porting services that I offer for the 2ZZ-GE engine.
I welcome any questions or feedback about the ported header.
So - What is a ported header? Why is it a good thing.
Easy answer - here are some pictures of the stock header:
Stock Header Inlets:
Here is a closeup of the inlet to one of the runners:
Here is another closeup of the inlet:
Some pictures of the stock collector:
Because this process uses the stock header as the basis, it will NOT affect emissions and will pass any CARB or other visual inspection.
Cheating is wrong and morally incorrect - its a shallow voctory if you win by cheating - some would say you have already lost. This being said, this modification will pass an EXTERNAL visual inspection for a bone stock spec race class in SCCA, NASA, etc. It is also legal in SOME classes that specify modifications are legal within a certain distance from the engine, etc. The odds of getting caught even on a teardown are very slim, but I make no gaurantees - you can always take the stance that this is a stock part that was simply repaired to correct a factory defect. If you would simply like the glaringly horrible parts of the weld in the collector addressed and no chnages made that would counts as an illegal modification I am certainly capable of doing that at a greatly reduced price. To stay proper with the rules be sure to check with the sanctioning body you race with to see if this modification is allowed before performing it. I will be happy to talk to them to answer any questions they may have.
The ported headers retain all factory mounting points, heat shield mounting points, and retain use of the stock support bracket. (unless removal of mounts is requested)
Flowbench Testing on GTS headers to date indicates over a 10% gain in flow from this operation. Increases may be slightly larger or smaller in some cases depending on the quality of the initial factory welds at the collector and the alignment at the inlets.
Total Header Increases were tested at (stock) 750 CFM average at 28" vacuum to (ported) 796 CFM average at 28" vacuum.
Individual runner flow increase is equally significant - from (stock) 205 CFM average at 28" vacuum to (ported) 236 CFM average at 28" Vacuum
2ZZ-GE header porting
(I don't want to give away all my secrets so I am not showing the current gen finished product, but heres enough to give you the gist of what I do - I will say that the knife edging in the collector had to be backed down a little as tube alignment issues make it impossible in some cases. There is still a taper but not so extreme)
Dyno gains will vary in accordance with other mods to your vehicle. The only dynos available so far are on a 2003 GTS with stock ECU, AEM CAI, and TRD Exhaust. And a 2003 Celica GTS with a Injen CAI and a HKS hiper exhaust. As you will see below there were gains of over 10 WHP and 10 WTQ at various points in the power band. om the first and about 5 WHP peak on the second. It is my belief that the gains from this modification vary largely depending on other mods on the vehicle.
Jay and Buz will both be providing before and after dynos shortly.
Click Here to view Swing Fixer's comparison Dyno
Click Here to view Klutch's comparison Dyno
Here are some of the initial reviews:
Originally Posted by Swing Fixer
Right now all I can saw was that i felt a noticable difference in power driving it home. Car definitely pulled much harder than with the stock manifold.
Originally Posted by Swing Fixer
great product and service!
My car was the test car of the dyno numbers that Boosted linked to. The very first time I drove it home after we installed the ported header I felt a HUGE difference. The car is much more fun to drive around since the gains we saw were in the RPM range of daily use. The dyno runs were on a Dyno-Dynamic dyno which is stingy when it comes to peak HP and TQ readings compared to a Dyno Jet.
Those numbers were with an unmodified and untuned stock 2003 ECU with AEM CAI and TRD Exhaust.
Turn around time is usually 2 weeks, although it is often less, and can be more depending on circumstances
Heres the price breakdown:
The total price will be Labor and supplies + shipping, with a refundable core charge if you do not send me a header to port. If you send me a header there will be no core charge.
Labor and supplies:
2ZZ Header - $155
Aftermarket header (DC, Hotshot, Trial etc) - Porting fees will be billed at a rate of $50 / hour.
Shipping & handling:
I ship Fed-Ex Ground unless expidited shipping is required. Cost is $20 for a Lotus 2ZZ manifold.
The big benefit of the core system is that you can order a header and get the ported header ready to go without having to have your car out of comission for a week or more. The new header arrives fully ported and you send your old header "the core" back to me after it has been replaced. I am going to try and find some used manifolds of all styles so I can bring the core charges down, but on a lot of these I am going to have to buy new manifolds to get the ball rolling. As such you will be requred to pay a refundable core charge that is equal to my purchase cost for a new manifold. If you keep the manifold I send you and don't send me yours back I keep the core charge to replace the manifold. You are responsible to pay shipping on the core. The core must be returned within 2 weeks of receipt of the Ported manifold, or $40 / week will be deducted from the core refund for weeks after 2 weeks.
April 2003 and newer GTS or Lotus Elise
- $230 (has air injection system tube)
Follow the link below to a guide to help you determine which manifold you have. You will have to register to view it but its free to register so no worries:
Celica Header Idetification - NewCelica.org Forum
Ceramic Coat for Header - $170 for the air injection style headers
It adds 2-4 weeks to the process
Here is an example of a Silver Ceramic Coated air injection header. VERY sexy.
Here are some pictures of a gold/bronze header with the mounting points removed (the color that is supposed to be the most thermally efficient)
Heat shield mounting point removal - $100
Air injection tube removal and welding - $30
Use of new air injection blockoff style header as core (no core return required) $250
$50 per header for numbers after porting.
$90 for before and after numbers on the same header.
$90 / Hour for flowbenching other components
Manifold and donut Gaskets:
I canl provide pricing on stock gaskets upon request
Payment and shipping information:
I take payment through paypal only.
The Price is the $155 porting fee + $20 shipping + the cost of any additional services you require (such as core exchange or ceramic coating)
At this time the headers are built to order. I usually have Lotus cores in stock, but I only have 3 so a sudden surge in business or a couple people slacking on returning cores will cause a delay. Obviously sending in your manifold is the best wat to ensure there will be no core related delays
I will update this thread as more info becomes available.
So let me know what you think, and if you have any questions. Just don't ask me how much power it makes on the Lotus or how well it stacks up to XXX header on a lotus, as we haven't completed any testing yet
References and more info:
Theres a long thread but if you want to see input from tons of happy customers and answers to lots of questions other folks have asked just follow the link:
Ported Headers by Boosted2.0 - NewCelica.org Forum