Ported Headers by Boosted2.0
This thread exists to provide information about the ported GTS and GT headers (exhaust manifolds) which I will be selling, 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!
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:
Quote:
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.
Quote:
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.
Heres the price breakdown:
The total price will be Labor and supplies + shipping, with a refundable core charge if you do not send me a header to port. If you send me a header there will be no core charge.
Labor and supplies:
GT Header:
$110
GTS Header:
$150
GTS or GT aftermarket header (DC, Hotshot, Trial etc) - Porting fees be the same or less than the cost of porting stock header
Shipping:
Depends on what you want - I will charge you exactly what UPS or FED-EX charges me for the type of shipping you want
Core charges:
The big benefit of the core system is that you can order a header and get the ported header ready to go without having to have your car out of comission for a week or more. The new header arrives fully ported and you send your old header "the core" back to me after it has been replaced. I am going to try and find some used manifolds of all styles so I can bring the core charges down, but on a lot of these I am going to have to buy new manifolds to get the ball rolling. As such you will be requred to pay a refundable core charge that is equal to my purchase cost for a new manifold. If you keep the manifold I send you and don't send me yours back I keep the core charge to replace the manifold. You are responsible to pay shipping on the core. The core must be returned within 2 weeks of receipt of the Ported manifold, or $40 / week will be deducted from the core refund for weeks after 2 weeks.
2000-Early 2003 GTS - $150
Feb 2003 - March 2003 GTS - $230 (no air injection but uses manifold with blockoffs)
April 2003 and newer GTS - $230 (has air injection system)
All years GT - $230
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 $140 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)
Manifold and donut Gaskets:
I will provide pricing on stock gaskets and will re-sell them at retail cost to save you a trip to the dealer if you want new gaskets
Port matching to a specific Gasket:
Add $10 to cost of manifold and Gasket
Payment and shipping information:
Will provide this information on or before March 1st when headers go up for sale.
Availability:
I intend to sell these on an "In Stock" basis whenever possible and I will not exceed more than 2 pre-orders for any one type of manifold I do not have in stock. Translation: At worst there will be one guy in line ahead of you for your particular manifold style.
Please note these are INITIAL PRICES. They will probably not go down, but they may increase if I find my costs have exceeded initial expectations. Thease increases will of course affect only sales I have not already agreed to a price on.
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
For engine build power gains plase try the following link:
__________________
Team Mechanic - Controlled Inertia
1990 Celica Alltrac Turbo
Last edited by Boosted2.0 : 10-11-2006 at 10:54 PM.
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