renegade intake? for cross fires

[Grumpy]

The melrose exhaust is a very well designed system, and keep in mind the exhaust gasses travel to the rear and pass through the (X) pipe they dissipate HEAT and loose some pressure and volume as a result, the (X) tends to mellow the growl slightly also, thus the two exhaust pipes past the (X) pipe share the split flow ,thats now sharing twice the original exhaust cross sectional area, at a reduced restriction, if I had the cash available thats the route ID suggest going , then you just need a decent quality, low flow restriction set of mufflers, added to the exhaust


http://www.superchevy.com/how-to/vemp-1007-corvette-headers-guide/?cx_source=cxrecs#cxrecs_s

http://www.superchevy.com/how-to/vemp-1008-corvette-headers-guide/

http://www.superchevy.com/how-to/ex...-exhaust-manifolds/?cx_source=cxrecs#cxrecs_s

http://www.superchevy.com/how-to/0501vet-long-tube-headers/

one of the better current c4 corvette exhaust system designs is made by www.melrosecorvette.com


two stainless mufflers similar in design to this with a 3" inlet and dual 2.5" outlets seem to match the application, but measure very carefully after the exhaust is installed to verify you have the required clearance to mount and correctly connect them of course, before ordering
http://www.jegs.com/i/Flowmaster/389/80430402/10002/-1?parentProductId=1030933

 

[Gibbles]

Looking at those links i did further research into other options, many sources no longer offer anything for the c4.

After looking at finances i went ahead and pulled the trigger on the Melrose system.

I'll still go ahead and break in the new camshaft with the old manifold to prevent damage to the coating on the new system...

I also could not find anything on what to expect for turn around from Melrose...

And from what i could find those fm 40's should be what i'm looking for in regards to sound...

Pretty much on the original system i have no cats, and over the summer while i had the exhaust system off for ujoints i emptied what i assume was muffler innards.

I had pretty much what i wanted for sound, standing behind the car while idling my ears would ring a little

 

[Indycars]

After looking at finances i went ahead and pulled the trigger on the Melrose system.

Sounds like you won't regret your decision, the Melrose looks to be a
very nice exhaust system.

I'll still go ahead and break in the new camshaft with the old manifold to prevent damage to the coating on the new system...

Is the manifold really going to make any difference in the AFR ...... or
maybe you have another reason ???

I also could not find anything on what to expect for turn around from Melrose...

Is the exhaust really going to be holding you up ???

 

[Gibbles]

Main reason is the prelube i used in the cylinders, per the melrose instructions break-in lube can damage the coating.

That and i have the factory manifold installed...

And no it won't hold me up at all at this point.

I just need to complete the fluid coolers and im ready to install the radaitor, once that's done i'm ready to prime the oil system one last time, install the dist and fire it up!

 

[Gibbles]

I broke in the camshaft last night, it went pretty well except for a little fire...

I learned open top valve covers are not a good idea unless you have someone watching the engine for you.

While keeping the rpm up i watched the driver side, i saw a little oil splash but it did not seem bad enough to worry to much.
What i couldn't see was the oil dripping down the exhaust manifold on the passenger side.

The good news is while prepping for this i bought a nice set of ABC rated extinguishers for the garage.

Also no damage to anything, i did get some powder on the passenger side rockers prompting me to disassemble and clean the rockers ect.

I still need to set the timing and balance the throttle bodies ect.

And no news on the Melrose exhaust system, hopefully not much longer.

I also could not find anything on what to expect, but i also did not find any complaints other than people being stupid.

 

[T-Test]

I broke in the camshaft last night, it went pretty well except for a little fire...

I learned open top valve covers are not a good idea unless you have someone watching the engine for you.

While keeping the rpm up i watched the driver side, i saw a little oil splash but it did not seem bad enough to worry to much.
What i couldn't see was the oil dripping down the exhaust manifold on the passenger side.

The good news is while prepping for this i bought a nice set of ABC rated extinguishers for the garage.

Also no damage to anything, i did get some powder on the passenger side rockers prompting me to disassemble and clean the rockers ect.

I still need to set the timing and balance the throttle bodies ect.

And no news on the Melrose exhaust system, hopefully not much longer.

I also could not find anything on what to expect, but i also did not find any complaints other than people being stupid.

I use to use the clip on oil deflectors while adjusting valves and such. Now I have an old set of tin valve covers that I cut the tops out just enough to do what is needed.

 

[Grumpy]

 

[Gibbles]

Yeah, I did exactly that to my old cast aluminum set.

Pretty much I drilled a series of small holes in the shape I wanted, then knocked it out with a hammer.

The issue was the roller rockers puddle oil in the center, and at 2500rpm it apparently splashes it all over the place.
I think they will work just fine at idle speed.

anyways I did the first oil change, the oil did not have any sparkles, the only color I could make out looked like the cam lobe pre-lube that came with the crane camshaft.

I changed the oil and filter, and added more break-in additive, next weekend I'll time it and see if I can get it running a little smoother, adjust valves, ect.

 

[Gibbles]

I got a surprise in the mail today.

For anyone ordering a melrose exhaust or header, i did not get any communications other than a order confirm.

however it looks like once the order is marked as "completed" it means it shipped.

I would have seriously liked a tracking/shipping notification but meh, it arived quickly well packaged and gorgeous!

I figured i should put my 2 cents out, i could not find anything on what to expect with my melrose corvette order.

 

[Grumpy]

glad to hear everything's working out as expected!
pictures are always nice??

 

[Gibbles]

I'll get pictures soon, this weekend I'll start the swap after i set the timing.

I had actually just called them today looking for a general eta. I got one confused guy on the other end, my last name is the same as a certain corvette supplier, that only made it harder.

I never did get a call back, however i'm sure they figured i would find a surprise waiting for me...

 

[Gibbles]

I'll get some detailed pictures of the exhaust this weekend using lighting and the good camera.

I had this on my phone, my redneck radiator fan for the camshaft break-in (it blows into the radiator).

I wanted to avoid having to fully install everything since I have to pull the radiator out again in order to complete the fluid cooler mounting...
It was cold enough that it actually worked, I held a steady 209f



And this is my current idea for the fluid cooler mounting, it uses mostly existing holes...

From there the aluminum pieces are riveted to each other, currently my idea is to install a few vertical pieces to serve as a mounting for the coolers, then I can mount a fan directly to the cooler it self.

I'm open to other ideas...

 

[Grumpy]

so far it looks good!, just be sure that fan pushes air down through the cooler and the radiator behind it draws air through it as normal with the fans behind it, every once in awhile I see guys make the mistake of mounting a oil or trans fluid cooler in front of the radiator and have the fan spinning in the wrong direction, remember if you swap the power and ground leads by mistake on some fans it rotates backward or reverse under power, while this is rarely an issue and I doubt youll have problems

 

[Gibbles]

Yeah, i can see the fan flow getting a little confusing. Last time around i had to verify the flow by getting on the ground and watching what way it turned.

I bought a pretty cheap fan last year as a pusher, this go around i'll spend a little more on a better fan, maybe two...

I'm thinking a pair of 10in side by side...

 

[Gibbles]

And i installed the headers last night, it took more energy drinks than i think you should drink in a single day...

So a few issues, first the number 2 and 8 spark plug boots contact the headers...
I think some shorter spark plugs would do the trick...

And the number 5 plug... In order to install i have to loosen the header to gain about a half inch in order to install the spark plug and boot.

Once installed and the header is bolted into place the plug and boot clear the header just fine.

I think a shorter plug would do the trick...

(Also i have pictures of the headers i'll post later on.)

 

[Gibbles]

Overall the install went pretty smooth, i did remove the starter to get a little more clearance, and then i used a jack stand to hold the header up to get clearance to reinstall the starter.

Doing that i avoided having to buy a mini starter... However while writing this i'm thinking i should have sprung for one... To remove that starter again...

And for the exhaust tubes... In a C4 you have to remove sections of exhaust if you need to change things like ujoints, seals, cables, ect...

The tubing is a pretty tight fit, so i beveled the edges, then using some 220 grit paper i softened the edges and smoothed the mating parts, then finished up with some 1000 grit.

Assembly i have this little jar of copper anti-seize from jeggs, using its little built in brush i coated the inside of the slip joint and spread it around with my finger.

What i'm not sure of is if it will damage the ceramic coating.

I attempted to call melrose to ask yesterday but they were already closed by then.

Installing the first set of tubes off of the header collectors went pretty smooth, on the driver side i had to remove the shift cable bracket and loosen the header to get clearance, once the tube was installed i had enough clearance to tighten the header back down and to reinstall the shift cable bracket.

Next issue is the hanger, my original had to be removed, however searching around and looking at hanger options the front hanger from a lt1 equipped corvette looks like it might be compatable...

So i have one coming, hopefully i'll have it by next weekend.

 

[Grumpy]

glad too hear everything's progressing about as most of us would anticipate,
and as always, it would be helpful if you could take and post a couple clear detailed pictures,
of the install from various angles, and lighting etc.
that would be great here!
especially because very few people seem to have that skill set ( ABILITY too POST clear photos)

 

[Gibbles]

Once i have the exhaust in I'll see if i can get some clear pictures of under the car as well.

So far I'm pretty happy with the way it's hanging, i doubt I'll have any issues with scraping ect.

They did a pretty good job on the design, especially on the driver side.

It gets pretty tight with 3in pipe around that shift cable bracket.

 

[Indycars]

Progress is good !

It's always a compromise.

 

[Gibbles]

Melrose header pictures...






There are some imperfections in the coating inside the primary tubes, I doubt it's an issue.