Ported Headers by Boosted2.0

[Boosted2.0]

This thread exists to provide information about the ported GTS and GT headers (exhaust manifolds) which is a service I provide, and to allow a place for questions and feedback about the same. Please use other threads for any posts not directly related to this topic. Thanks!

To get right to brass tacks:
$155 for 2ZZ exhaust manifold porting
$115 for 1ZZ exhaust manifold porting
$20 shipping and handling (local pickup in Houston is available and is free)
$145 for ceramic coating (Comes in Gold, Black, Grey, and polished silver)

If you are local and want installation PM me for price / labor rates.

Core exchange program:
If you want me to port a header I have in inventory and send it to you and you send me back your old one to minimize downtime I can still do that. Its called the core exchange program. The following core charges are 100% refundable if made in a seperate paypal payment or 97% refundable if made as part of a single payment.

Original 2ZZ manifold - 00-early 03 - $150 core charge
Air injection or air injection blockoff 2ZZ amnifold - 03 - 05 - $235 core charge
1ZZ manifold - all GT models - $235 core charge



OK - so with that out of the way on to the Technical info:
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 teh 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. It will also pass an EXTERNAL visual inspection for a bone stock spec race class in SCCA, NASA, 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)

The ported headers retain all factory mounting points, heat shield mounting points, and retain use of the stock support bracket.

Flowbench Testing on GTS headers to date indicates over a 10% gain in flow from this operation. (These results will be updated if they change as test sample sizes increase). Increases may be slightly larger or smaller in some cases depending on the quality of the initial factory weld at the collector.
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



GTS header porting (I don't want to give away all my secrets, but heres enough to give you the gist of what I do)

Ported Inlet


Ported Collector:


Dyno gains will vary in accordance with other mods to your vehicle. The only dyno available so far is on a 2003 GTS with stock ECU, AEM CAI, and TRD Exhaust. As you will see below there were gains of over 10 WHP and 10 WTQ at various points in the power band. It is our belief that with a more freely breathing setup significant gains would have prevailed throughout the entire RPM range.

Click Here to view Swing Fixer's comparison Dyno

Click Here to view Klutch's comparison Dyno


Flowbench testing on the GT Header is now complete. Testing shows huge single runner increases of anywhere from 35% to more than 55% from 119 CFM at 28" vaccum to 185 CFM at 28" vacuum. Total flow increased from 615 CFM at 28" to 654 at 28". Further test results will be available as dynos are completed.

The only recipient so far has been Swingfixer. Here are his 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.

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:
http://www.newcelica.org/forums/showthread.php?t=205642


Additional Services:

Flowbenching -
$50 per header for numbers after porting.
$90 for before and after numbers on the same header.
$90 / Hour for flowbenching other components

Ceramic Coat for Header:
Ceramic coating is now available.
The price is $145 for Normal GT or GTS and $170 for air injection 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 (the color that is supposed to be the most thermally efficient)





Port matching to a specific Gasket you supply:
Add $10

Payment and shipping information:
Will provide this information on or before March 1st when headers go up for sale.



Instructions on removal and installation of headers
http://www.newcelica.org/forums/showthread.php?t=205898

I will update this thread as more info becomes available.

So let me know what you think, and if you want one. Make sure you get your production date off the VIN sticker on your drivers door if you have a 2003 model year.

For additional inexpensive power gains try the following link:
http://www.newcelica.org/forums/showthread.php?t=226688

[Boosted2.0]

Cliff Notes:

GTS Headers $150
GT Headers $110

Up to 10 HP and 10 tq at certain points in the RPM band.
Pending for sale date is March 1st.

Shipping is extra.

Send me your manifold and there are no additional charges. Otherwise there is a Refundable core charge

[youngxlos]

nice, so wat gave you the gains? flowbenching the header?

[coo880]

is it 150 dollars + send you our core? I was going to buy a header from you but then this guy has to ask his friend but i need the header asap. You think i can send you the header on thursday and get it back next week? How much will it cost not including shipping.

[Smaay]

Boosted, lets see a few pics of the porting

[Kenbx84]

doesnt blue bomber do this for like 75$?

[GTSunami]

why did you have to move to texas??? I would do in a heartbeat if you're still here in Carson!!!!!

[Boosted2.0]

Originally Posted by youngxlos

nice, so wat gave you the gains? flowbenching the header?

Flowbenching is how I have been testing and proving the particular method I use. The porting job that I do is what causes the gains. The Flowbench numbers are a tangible measurement of the difference in flow.

Originally Posted by coo880

is it 150 dollars + send you our core? I was going to buy a header from you but then this guy has to ask his friend but i need the header asap. You think i can send you the header on thursday and get it back next week? How much will it cost not including shipping.

Yes its $150 for the port job + send me the core. Yes, if you sent it overnight on Thursday I could have it back to you by next tuesday no problem as long as you are willing to pay overnight shipping. If it gets here early enough on Friday I might be able to get it back out Saturday. If you don't want to send a core up front then add the appropriate core charge for your model and model year. If you send the core back in a timely fashion then you get all of your money back.

Originally Posted by Smaay

Boosted, lets see a few pics of the porting

I'll get some pics up tomorrow most likely

Originally Posted by Kenbx84

doesnt blue bomber do this for like 75$?

I seriously doubt it. I've got about $2.5K into this project in tools, materials and time so far. To my knowledge all the port jobs done up to this point have been done on the basis of "Hmm this LOOKS better" with no measureable proof of any kind. I also doubt they are doing the same thing I am or providing the same quality of workmanship.

Originally Posted by GTSunami

why did you have to move to texas??? I would do in a heartbeat if you're still here in Carson!!!!!

Sorry bro - we had a kid and the whole single income thing made Cally untenable. Still Smaay can install the header no problem if you want to buy one, and if you paythe core charge you get a ported header up front so there is no down time for you car, then I give yo the money back when you send me your old one.

[Boosted2.0]

Oh - I forgot to mention. If you have some special setup on your car and you think there would be some value to the community to a before and after dyno of your car with this ported header as the only difference and you are willing to pay for said dynos, drop me a PM and we will talk about discounted pricing.

Basically I am looking for:

One car bone stock
One car with Injen and Kazuuma
One car with De-cat and some kind of high flow exhaust and intake

I am also sending a free header out to a gentleman with a CAI, decat, exhaust and Power FC to see what gains are there to be made with that setup.

[itchyvi3t]

boosted im interested in this, im guessing you dont have 03+ headers in stock? my car is going to be worked on for in about 2 weeks and i figured i coudl just take the header off and send it while it gets worked on, can pm me for more details please

[timm3r]

im way interested. But what makes your ported header different from a normal diy ported header? i can port my own header for free with a die grinder, what makes yours so much better?

[Kenbx84]

he has more time invested in research and is dyno proven..the diy jobs people do doesnt have any solid background or proof to it...im actually interested in this.

[oONoGoAutoOo]

im definitely interested.

[Boosted2.0]

Originally Posted by timm3r

im way interested. But what makes your ported header different from a normal diy ported header? i can port my own header for free with a die grinder, what makes yours so much better?

Actually you can't do it for free. Could you do it yourself? Sure. But you're going to have to shell out some bucks for new tools (I am all too painfully aware of how much at this point)

The header is cast iron and steel. Normal dremel and die grinder bits get consumed in a heartbeat. You have to buy specialty porting tools which will cost as much as the cost of what I do. Plus if its your first one its going to take you over 6 hours and the odds of you catching everything I have found that needs to be corrected and duplicating the finish I am able to create is pretty low. Plus teh time spent makes it very difficult to do in a day - your car is going to be down for 2 days at least.

And at the end of it all you will just have to hope its as good as it can be. I'm STILL testing to make sure that when the first ones go up for sale on March first they will make every scrap of power possible. I have already spent a couple hundred bucks on flowbench time alone.

So there you go - drop a couple hundred on some new specialty bits and a high dollar grinder and a compressor that can actually turn it, and then another couple hundred on some flowbench work to make sure that the job you did is every bit as good as it can be. OR you can just buy one from me, KNOW thats its right, KNOW you are getting the most out of the mod, and get it changed out same day without the callouses, cuts and burns to show for it.

BTW - the reason this is as expensive as it is is that I am having to buy $40 in specialty carbide bits and polishing media PER MANIFOLD to ensure the proper surface finish. Anything besides the expensive bits takes 3 times as long and comes out much rougher unless you spend another 3 times as long polishing.

Thats why I was finally willing to post pictures. I realized that even being able to see SOME pictures of the final product, as long as I kept the price reasonable, theres no reason to DIY - its just way too costly and time consuming.

[Boosted2.0]

Originally Posted by itchyvi3t

boosted im interested in this, im guessing you dont have 03+ headers in stock? my car is going to be worked on for in about 2 weeks and i figured i coudl just take the header off and send it while it gets worked on, can pm me for more details please

Correct - I have no 03 GTS headers in stock besides the one thats going on the Lotus and its been modified to cap off the air injection line.

2 weeks will be plenty of time to turn it around.

[timm3r]

now your dyno was done without a tune right? those are some pretty good numbers for the amount you are paying. i wonder how much increase you will get out of this with a tune.

[Boosted2.0]

Originally Posted by timm3r

now your dyno was done without a tune right? those are some pretty good numbers for the amount you are paying. i wonder how much increase you will get out of this with a tune.

Yup thats a bone stock 2003 ECU.

I expect the numbers will be downright awsome with a decat, high flow muffler and a power FC (or Camcon / em-manage for the 03 guys)

[Boosted2.0]

Originally Posted by Smaay

Boosted, lets see a few pics of the porting

Done - pics added to original thread.

[timm3r]

you dont have any pictures of the ported collector do you?

[Carbonized_GT]

would you be interested in doing a 3SGTE Manifold(if its possible)

[purplecowofdoom]

Wow, impressive gains early in the powerband. That's what I like to see As soon as I have the money, I'll take one. Probably about a month!

[Boosted2.0]

Originally Posted by Carbonized_GT

would you be interested in doing a 3SGTE Manifold(if its possible)

If you send me the gasket, manifold and turbo I can port match all of it. Ideally you should also have the head port matched to the gasket.

[Boosted2.0]

Originally Posted by timm3r

you dont have any pictures of the ported collector do you?

You mean besdes the one I posted above? That bottom pic is one half of the collector (the sepreator plate blocks the other half from view - If I zoom out any more the collector goes out of focus)

Besides I'm not writing a DIY guide here - I don't WANT you to know exactly what I do if you plan on doing it on your own

[youngxlos]

uhhhhmmmmmm

[SuuPaSeDan]

this is definately a good idea...

let me see if i can dig up the cash for it, i want to be the first GT in line

[Boosted2.0]

Originally Posted by youngxlos

uhhhhmmmmmm

Still confused? Maybe you can expand your question and I can answer it more clearly.

[Jdm_cel]

Originally Posted by Boosted2.0

I am also sending a free header out to a gentleman with a CAI, decat, exhaust and Power FC to see what gains are there to be made with that setup.

Are you still looking for this person/ tester??
I'm interested if this spot is available....
If there is already a tester... please keep me up dated on the result...

[celicajonz]

what would be the price i f i sent u the header, brand new? 04 gt-s version???

[Boosted2.0]

Originally Posted by Jdm_cel

Are you still looking for this person/ tester??
I'm interested if this spot is available....
If there is already a tester... please keep me up dated on the result...

What are your exact mods and are you willing to do before and after dynos?

[MicaCeli]

So how many of these headers can I put on my car and what would the power increase be?

[Illusive]

Originally Posted by celicajonz

what would be the price i f i sent u the header, brand new? 04 gt-s version???

It says right in his first post bud.

[Boosted2.0]

Originally Posted by celicajonz

what would be the price i f i sent u the header, brand new? 04 gt-s version???

If you send it to me its $150 +shipping

[Boosted2.0]

Originally Posted by MicaCeli

So how many of these headers can I put on my car and what would the power increase be?

You can only run one at a time unless you make an adapter I suspect you would find the gains for a second or third one on the same car somewhat dissapointing

[Swing Fixer]

BUMP for 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.

[celicajonz]

...thanks for the info.

[Boosted2.0]

Originally Posted by celicajonz

...thanks for the info.

No problem!

[CELICAonaPROWL]

Originally Posted by SuuPaSeDan

this is definately a good idea...

let me see if i can dig up the cash for it, i want to be the first GT in line

As soon as Dave is done with the GT header and it gets sent back to me, i'm going right down to the dyno shop to get before/after dyno comparisons. That way, us GT will have numbers to go off of.

[SeeULater]

Since you have all the tools and after you do almost everyones header that wants it done you should try a P&P on a head! You could make a great deal of money off of this because MWR charges way to much for a P&P with flowbench. Just some food for later thought. I know you are going to be busy with what you have going on right now for quite some time now. Great work! I think everyone thanks you for what you are doing for the celica community.

[SikSully]

whoa where can i order this from...

[celicarida]

Boosted2.0 can you ship to canada?
If so im in for sure
2000 celica gts

[Illusive]

Originally Posted by SikSully

whoa where can i order this from...

directly from boosted2.0 lol. I'm sure if you pm him he can give you more details on the way he plans to work out orders.

[Boosted2.0]

Originally Posted by CELICAonaPROWL

As soon as Dave is done with the GT header and it gets sent back to me, i'm going right down to the dyno shop to get before/after dyno comparisons. That way, us GT will have numbers to go off of.

Its been done for a couple days but I'm going back to do final flowbench on it this Saturday - I'll ship it to you ASAP next week.

[Boosted2.0]

Originally Posted by SeeULater

Since you have all the tools and after you do almost everyones header that wants it done you should try a P&P on a head! You could make a great deal of money off of this because MWR charges way to much for a P&P with flowbench. Just some food for later thought. I know you are going to be busy with what you have going on right now for quite some time now. Great work! I think everyone thanks you for what you are doing for the celica community.

I have thought about this, but you cannot properly port a head unless you have a flowbench, as you need to be 100% certain all cylinders flow equally to do a quality job. This would mean numerous trips to the flowbench for me which will become very time consuming and expensive. Instead another member of Controlled Inertia has sent a complete cylinder head to the best 3S-GTE porter in the country and he is working with him to see what he can do with the 2ZZ head. I talked to him about it at length and we both agreed that it looks like most of the gains will be on the exhaust side.

Anyways if I make enough off this project to buy a flowbench of my own then I may start doing heads, but probably not until then.

[Boosted2.0]

Originally Posted by SikSully

whoa where can i order this from...

From me - They become available on March 1st - readthe whole first thread and all the information is there.

[Boosted2.0]

Originally Posted by celicarida

Boosted2.0 can you ship to canada?
If so im in for sure
2000 celica gts

I don't see why not. Not sure what it costs or anything, but shouldn't be too bad. PM me with an address and I'll look into costs for shipping for you.

[SeeULater]

That is what I figured!

[kabal57]

Wow, a big help down low where the gt-s needs it.
Question though, I remember reading that you think the high end was suffering because of restrictions with the cat, Can you guesstimate what we'd be looking at over 6k rpms with the cat removed & a straight pipe?
I know it sounds like a stupid question, I'm just curious if you have any ideas on how it would look based on the gains down low. Which brings me to question #2, by removing the cat do you think that below 6k would gain even more than +10 +10, or would it not be a factor?

[Pulsar1]

Looks like a good deal, how hard is it to remove the header off the engine, looks so tight back there. Are air tools a must or can you use regular hand tools?

[sbocaj55]

I'm not buying a ported header from Boosted2.0, but I'd like to add that I think this is a good deal. I will most likely be porting my own header, but that's simply because I have the tools and have access to flowbenching if I wish from a friend's shop. I am hoping for ~5hp. If he can give you 10whp for $100-$150, that is hella cost efficient. If you do it yourself you'll need some pretty decent air tools which cost a lot, and a couple solid hours to make ~5hp, much less 10hp.

[Boosted2.0]

Originally Posted by kabal57

Wow, a big help down low where the gt-s needs it.
Question though, I remember reading that you think the high end was suffering because of restrictions with the cat, Can you guesstimate what we'd be looking at over 6k rpms with the cat removed & a straight pipe?
I know it sounds like a stupid question, I'm just curious if you have any ideas on how it would look based on the gains down low. Which brings me to question #2, by removing the cat do you think that below 6k would gain even more than +10 +10, or would it not be a factor?

I think if you had a decat and straight pipe and a good high flowing intake the HP and torque curves would maintain the same sepration they do at low RPMs (or close to it) until you hit the slow limits of the next lowest flowing part.

The Decat and straight pipe will help bottom end a bit more, but not nearly as much as it will help the top end.