TTS Equal Length 1-5/8" Headers & 2-½" Y-pipe Installation

Here are the TTS equal length headers before installation. Notice the extra-thick 5/8" fly-cut anti-warping flanged included.

Here's a shot of the inside of the ports themselves. Each header is first tack welded to the flange, then individually welded from the backside to eliminate leaks.

The first order of business is to remove the stock manifolds, which is no easy task on an F-body. Most of the work is done from the bottom. Here you can see the stock passengers side cast iron manifold in place.

Here's the view from the drivers' side. A little more room, but not much. Notice the AIR fittings...those are the stock pieces. The TTS headers are the only ones I know of that utilize all the stock fittings and hoses.

Just to the left of the white oil filter, you can see the drivers' side cat. This cat uses just under a 2¼" crossover pipe.

Here is the configuration of the stock Y-pipe. The drivers' side cat is connected directly to the manifold (depicted in the previous picture), while the passenger side cat is beside the transmission. The two crossover pipes "Y" together after that point. The cats and pipes are all just under 2¼" diameter, and the Y-pipe exits as a 2½" pipe before meeting up with my 3" Borla system.

Here's a view of the stock cats and Y-pipe from the other side of the car.

The TTS supplied catalytics are much nicer than the stock units. These were bullet shaped units of roughly 3½" diameter with their own integral heat shields.

Here is the measurement of the I.D. of the stock catalytic converter. A measly 2¼" diameter!

Here is the measurement of the TTS supplied catalytic converters. I.D. measurement showed 2½" diameter.

For comparison, here are the two cats side by side. See the difference?

When installing headers on an F-body car, the plastic heater box is often melted from the heat. The TTS headers are supplied with a custom fitted heater box shield.

Looking straight up from underneath the car, here is the heater box shield in place.

Once the headers were in, final fitment of the Y-pipe was done. The new Y-pipe is a full 2½" diameter from the collectors back to the cats. You can also see the position of the pre-cat O2 sensors in the collectors. Those O2 bungs are welded in place and tapped for quick installation when the headers arrive.

The two cats fit nicely side-by-side where the passenger side cat used to sit. Here's a shot looking forward at their placement. Here you can also see where the Y-pipe exits the cats and joins together at the 3" collector, then turns back toward the remainder of the exhaust system.

Once the Y-pipe and cats are in, we had to put in the post-cat O2 sensors. This is kind of a special setup on this car, so they were done during final assembly to make sure they cleared all the parts on the car. You can see the drivers' side post-cat O2 sensor right next to the transmission crossmember.

Here's a shot of the complete system installed. You can see that it all tucks up nicely and clearance is not a problem. The transmission is still the lowest point under the car.

Here's a shot of the drivers' side header in the car. Note the use of all the stock AIR fittings.