Trials, Tribulations, Rants & Raves on my headers, CATS and muffler install...

I thought to take a proactive approach to the problems with CATS disintegrating, mufflers losing its insulation (white powder). Getting a sweeter sound would also be an added bonus. I was able to use my new garage, with lift, to do the work. It took longer than what I expected and I would not want to do this again.

I searched F-Chat for options and prices, etc. I ended up with headers from Agency Power purchased through Vivid Racing, high flow CATS from Kinetix Racing. I was going to keep the OEM muffler, but while removing it, the mounting brackets bent off as there were massive cracks around the welds. Vivid Racing stepped up with a set of Fab Speed muffler and tips for the same price of the cheaper one I was looking at. They were also able to deliver it just a few days.

Removing the OEM system was a bit of a pain. Seats, rear interior panels had to be removed to access the panel to the front of the engine. Getting the old headers off was a very time consuming. While I was 'in there' I replaced the top transmission mount. I bought Hill Engineering mount and Ricambi tool for removal/installation. The aluminum brace over the engine had to be unbolted and lifted up to access the mount. The old isolator had tears in the rubber. I also wrenched on many bolts back there as many were not real tight.

Then the issues started. The new headers did not slide onto the studs!!! After looking close, I found that the two outboard studs (each end) needed clearance. I had to file the two holes outward for a total of approx. .06". The headers were JetHot coated so I thought to blow all pipes and ports out. Here I found one of the main SAI pipe was not drilled through to the pipe that feeds all of the individual ports!!!!! Had I just installed the header, I am sure there would be issues that would be hard to figure out. A call to Agency Power to bring this to their attention was treated like I was crazy and their products are perfect. Also close inspection of the welds show that there was 'burn thru' and weld beads that look poorly done. Agency Power is NOT recommended by me. A sharp contrast with the welds on the CATS and muffler. Had I known and seen the sale, I would have gone with the FabSpeed headers!!!!

Installing the passenger side headers took me about six hours!!! Getting the nuts stared is very difficult. Using an open end wrench to turn the nut a fraction, flipping the wrench and turn a little more, flipping, turning, flipping.... The upper nuts required me to lie on top of the engine, use a mirror and again the open end wrench, flipping, turning, flipping, turning... What a PITA!!!! The driver side was way better. The rest of the install went as expected. I got to a point where I could take the car on the road (less the rear bumper), but I wanted to feel and hear how this is turning out. I was not disappointed!!! The butt-o-meter felt like a smoother, faster acceleration and the sound is pleasing F1 sort of wail.

The pix here are: the headers as received, looking down the main SAI fitting where I had to drill through, header flange where I had to file the hole to a slot, here you can see how the stud fits to the flange, looking down to the header installed, the high flow CATS installed, rear view less the bumper.

I can't imagine what a shop would have charged to do all of this on an hourly rate. Also all of things that I found and fixed that might have been missed.

I suppose as I drive the car more, I will forget how bad this was and how much worst this could have been if I had to remove all because of the SAI issue.

Now I will be looking forward to dropping the engine on my 993 to do a new clutch/flywheel upgrade.
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There is absolutly no and I repeat, no space to wrap anything around the nut because the header tube is so close. Only an open end wrench can be used.

Even the head of the open end ratchet to too large.

 

You would think. They did not say sorry for any inconvience and we will do 100% inspection, thanks.... nothing, nada, zip. I hope this thread turns business away from them.

Agency Power lacks proper customer relations...

However-
The high flow CATS from Kinetix are beautiful, highly polished, came well packed, caps on all openings, First Class in my book!!!!

 

It will be a while until I can do this... I am out on travel, need to get my new Pilot Sport II's mounted/balanced, etc... When all comes together, I will see if a recording can be made.

Thanks for asking.

 

With the Agency Power headers, the tubes are so close to the studs and the bends start quickly that the edge of the hex nut almost touch the tube. Some of the nuts had to be started way before the header flange came in contact with the engine head. Once the flange was up to the head, there was NO ROOM to slip a socket over the nut, much less have a universal and extension. By the way, Agency Power said their mechanics have to do the open end wrench and flipping to do the install.

As to reaching all of the nuts from below... forget about it, the tubes are in the way!!! I have been wrenching for almost 50 years and know many work arounds, but this was a challange. I am glad they are now on, but I hope I never have to take them off!!!!!!

 

I think Vivid Racing suggested lift/tilt the engine and transmission some to get the little extra space needed. I used a transmission jack and a block of wood to do this. The old stuff is huge and heavy.

I now wish I had taken the time to document all of this, but alas, I didn't.