DC Header / ES2 Experience

[2ndGenGuy]

So, I thought I'd go ahead and toss my DC Sports header onto my ES2 this weekend. I wanted to see what I was going to be up against whenever I finally get around to the A20 swap.

So I got some plugs to fill in the bungholes (heh bungholes) for the O2 sensor ports. Very nice!
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2653.jpg

The EGR tube was pretty much broken when I got the header, it had been welded back on, but I didn't want EGR anymore anyways. I took it to a shop and had them weld in the hole. A new one can be welded in later...
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2652.jpg

Here's a pic comparing the factory 2.5g exhaust to the DC header. Everything looks like it should work! Sweet!
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2650.jpg

I pulled the whole exhaust system, since I needed to run my eBrake cables for the rear disc conversion.
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2631.jpg

Went ahead and hollowed out that plugged up cat. I couldn't see through the thing, so I dont know how exhaust could flow, or how the damn thing could even be working. I will probably pick up a high-flow cat soon.
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2640.jpg

The yummy platinum goodness that was inside the cat.
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2641.jpg

[MessyHonda]

how does it feel now?

[2ndGenGuy]

Pulled off the Air Suction and EGR Crap. EGR was plugged anyways and not doing a damn thing.
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2636.jpg
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2635.jpg

Chopped off the ends of the tubes so I could slide them neatly out from under the distributor and thermostat neck.
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2634.jpg

Made a nice EGR blockoff plate. Oooh shiney!
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2654.jpg

BAM, installed the header!
http://i66.photobucket.com/albums/h256/jgturk/DC%20Header/IMG_2655.jpg

BUUUT I ran into one snafu. Turns out that the 3g / DC header is about an inch or two longer on the downpipe than the 2.5g stock downpipe. The cat barely fit back up inside it's cozy compartment, and the hangers woudln't bolt up.

I bolted up the rest of the exhaust system, but it's all out of alignment too. Gotta cut a section out and shorten it just after the cat, and weld new hangers back onto place. I'm going to do this as my first welding project, so I'll update this thread as I go with new pics. Should be fun. For now, I have no muffler, just the hollowed cat and resonator. It gurgles and afterfires, and its kinda fun. :) But it's getting patched up this weekend.

[2ndGenGuy]

how does it feel now?

It feels a little more powerful. It threw the mixture way off and I had to retune the carb, so I don't know how you EFI guys deal with that. I think I need to change the main jets out, but I was able to just adjust the idle mixture with the screw.

The car pulls a bit better, but I don't really know if it's the header or the loud exhaust in my mind. Either way, Saturday will be a fun exhaust project. :)

[MessyHonda]

It feels a little more powerful. It threw the mixture way off and I had to retune the carb, so I don't know how you EFI guys deal with that. I think I need to change the main jets out, but I was able to just adjust the idle mixture with the screw.
The car pulls a bit better, but I don't really know if it's the header or the loud exhaust in my mind. Either way, Saturday will be a fun exhaust project. :)



sweet take some vids....every day your 2nd gen is more badass.

[LX-incredible]

Sweet. :thumbup:

[Ls1-Inside]

Ya gotta tell 'em about your Flame Thrower Explosions now!!! :eek:


-Dan

[2oodoor]

cool pics,
yea you get the butt dyno increase, the sound ...
you will feel it burst some at highway speeds, a power band that wasnt there before.
also you should notice you dont have to give it quite as much throttle to keep momemtum, but then that goes out the door if you keep wanting to hear it growl... haha
I cut those large flange nuts off the air suction tube on both ends, and welded a bolt head and washer in them to make them screw in plugs. Chunk the tube.

[BITESIZE]

Neato!!

[2ndGenGuy]

Ya gotta tell 'em about your Flame Thrower Explosions now!!! :eek:
-Dan

Oh yeah, it shoots flames out the tailpipe now. And has a nice LOUD backfire. It sounds like a gunshot. It's literally as loud as maybe a .357. I still haven't had a chance to fix the cat-back yet. I might get the header cut down to make it a custom 2gee DC header. :)

[2oodoor]

Oh yeah, it shoots flames out the tailpipe now. And has a nice LOUD backfire. It sounds like a gunshot. It's literally as loud as maybe a .357. I still haven't had a chance to fix the cat-back yet. I might get the header cut down to make it a custom 2gee DC header. :)
what the.....
you must be sucking air in the exhaust somehow, did you completly plug off the air valve doohicky at the intake and on the header?
flames making it to the talipipe surely is not good yes?
Carb a little off now or a lot off?

I used to do something like that, I had a plymouth road runner with hollow cat, and a four speed... I could be driving at road speed and slowley press the gas down and cut off the ign at the same time, one second, turn the key back on and Blamyeow, cannon. Got in trouble doing it to a cop who had somebody pulled over, he came after me and shook down my passenger, he thought he threw something out at him.. lol
same theory could be used, if you had some ign problem disguised as a carb problem... the chamber of the hollow cat holds some mixture if it aint being burned off or blowed out completly.

[2ndGenGuy]

what the.....
you must be sucking air in the exhaust somehow, did you completely plug off the air valve doohicky at the intake and on the header?
flames making it to the talipipe surely is not good yes?
Carb a little off now or a lot off?

It's not a constant flame, just an occasional backfire (technically an afterfire). It's only on deceleration, and it accompanies the familiar gurgle-pop associated with low-backpressure exhaust systems.

The Air-Suction and EGR systems are both capped off and sealed. The EGR port on the header was cut off and welded shut, and the O2 sensor ports have caps screwed into the bungs.

The header is capped off securely, and I installed new crush gaskets. The place there is a problem is after the cat. The whole exhaust is FUBAR from the cat back, I think there's a couple leaks, and it's not properly fitting in the exhaust channel because the DC downpipe is a few inches longer than the 2gee downpipe.

So, I'm either going to just have the cat removed, since it won't fit, or have the downpipe on the header shortened... Then have custom 2.25 inch exhaust the rest of the way back, with a Cherry bomb and that's probably all for now.

I'm sure the carb is probably running rich, as it's a bit stinky now, but I also gutted the cat... So perhaps that's the deal with that. I don't feel any power losses, but haven't had time to play with jetting either. I don't have a WBO2 sensor, so now way to know for sure unless it's running wierd... But it's running great, so I'm not too worried.

[2oodoor]

, you want it loud?
everybody is going to want some of you on the road... lol
I wouldnt cut the header
Sounds like you got a good plan in mind...

[snoopyloopy]

It feels a little more powerful. It threw the mixture way off and I had to retune the carb, so I don't know how you EFI guys deal with that. I think I need to change the main jets out, but I was able to just adjust the idle mixture with the screw. :)
we don't, the computer does. :) but anyway, looks good. almost makes me pick up a 2g one day and fix it up.

[Civic Accord Honda]

nice my car backfires some times but it more like a BB gun and no flame :(

[MessyHonda]

we don't, the computer does. :) but anyway, looks good. almost makes me pick up a 2g one day and fix it up.



yeah it helps a bit....but OBD1 would be better....yeah....2nd gen looks hot...only if i could find an se-i 5 speed.

[Boltgunner]

Pacesetter downpipe/header fits and 84 just fine, FYI.

Oufit in Bend, OR, took my OEM cat back pipes and made me a mandrel-bent equivalent! Mo heavy breathing is good! (visual - lusty red head babe panting...)

[Boltgunner]

By the way, you appear to have done what I will be doing, Webering up. Can you toss in some photos of the Weber setup from different angles, please? Also, any pros/cons lessons learned from doing this? Very grateful for your reply! :thumbup:

[Boltgunner]

Good people - http://www.4customexhaust.com/