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Old 05-22-2006, 11:14 PM   #1
txl146
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Default Impression: Borla header vs. Ported and coated exhaust manifold

With help of my buddy, we were able to take off Borla header and put ported exhaust manifold on today. Install went longer than expected because bolts were badly rusted and one of stud came off.

Impression:
Borla header: lack of low-end torque, but makes up with improved top-end power. Raspy sound that replaces famous boxer engine sound. Ideal for all out power.

Ported and coated exhaust manifold: good low-end torque and midrange power. Porting helps to improve top-end power slightly below power range of borla header. Car is noticeably louder with deep boxer rumble. Ideal for every day driving. In 1st and 2nd gear, car feels extremely smooth and powerful similar to feeling I had when I drove my buddy's STi.



My car is getting Protuned again on 6/7/06. Will post dyno chart for comparison (Borla vs. Ported stocker). Car dyno'd 262whp and 272wtq with Borla header. 80whp and 140 wtq @ 3000rpm.
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Old 05-22-2006, 11:38 PM   #2
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make sure to get some graphs of boost while you are dyno'ing.
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Old 05-22-2006, 11:54 PM   #3
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Please post a link in this thread when you do get tuned
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Old 05-22-2006, 11:56 PM   #4
txl146
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Quote:
Originally Posted by jdgrimm
make sure to get some graphs of boost while you are dyno'ing.
Of course. I'll keep the boost the same at 17.5psi.
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Old 05-23-2006, 01:03 PM   #5
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port looks good
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Old 05-23-2006, 01:44 PM   #6
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how long did it take you to swap im putting mine on soon
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Old 05-23-2006, 02:07 PM   #7
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took about 2 hours... damn stud.
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Old 05-23-2006, 07:03 PM   #8
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Spent some more time today driving around. Top-end power is reduced noticeably while low-end power is significantly improved. Car just doesn't pull hard anymore. It's possible that my car was custom tuned to work specifically with Borla header. My tuner (XX-Tuning) said that aftermarket header won't require a retune, but it's worth to recheck it.

Will find out when I get a protune again.
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Old 05-23-2006, 07:18 PM   #9
Chuck H
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Quote:
Originally Posted by txl146
Spent some more time today driving around. Top-end power is reduced noticeably while low-end power is significantly improved. Car just doesn't pull hard anymore. It's possible that my car was custom tuned to work specifically with Borla header. My tuner (XX-Tuning) said that aftermarket header won't require a retune, but it's worth to recheck it.

Will find out when I get a protune again.
Tuning makes a HUGE difference when you go back and forth between a header and the stock manifold. I had an EcuTek tune on my car with the stock turbo and stock manifold setup, but complete aftermarket turbo-back exhaust and uppipe. It made 227 whp on a heartbreaker DynoDynamics dyno and spooled insanely fast. Then I bought an unequal length header, had it ceramic coated (equivalent to Crucial Racing coating) and lost 40 hp and approximately 1000 RPM of spool. Had it re-tuned and managed to get back all but 7 hp, but I still spooled 500 RPM later. And the tuner had to play all sorts of games to spike the boost to even get back that much spool. Even with the ceramic coating the EGT's were just too low, and the header was letting the exhaust cool off too much.

I've since upgraded to a VF34 turbo and better intercooler. I'm almost curious enough to wrap the header and try it again, including running one step colder plugs and having the tuner play games with ignition timing and A/F mixture to try to keep the EGT's higher, but I'm not sure it's worth the $200 for tuning time just for an experiment. The VF34 with ported/ceramic coated stock manifolds spools about the same as the stock turbo did with the header. And I'm not willing to give up another 500 RPM of spool if that's what putting the header back on would do for me, even if it does mean a few more top end hp.
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Old 05-24-2006, 03:11 AM   #10
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I am thinking about going back to Cobb OTS map to see if it makes any difference. It may be safer to run OTS map until I get a new tune...
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Old 06-06-2006, 09:37 PM   #11
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I am getting a Protune again tomorrow. Will post two charts for comparison purposes.

1. With Borla header (262 whp, 272 wqt)
2. Ported and coated stocker ???

All parameters will stay the same (will try my best) including boost level, etc.
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Old 06-06-2006, 09:46 PM   #12
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get dyno'd elsewhere, JM2C.
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Old 06-06-2006, 09:49 PM   #13
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Why do you think that way I should get a tune elsewhere?
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Old 06-07-2006, 08:50 PM   #14
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Very strange things happened today. When I brought my car in for dyno at XX-Tuning today, baseline boost level was recorded to be around 19psi, up from 17.5psi. In April, car was tuned to run at 17.5psi...

Only thing that I did to my car since previous Protune was getting ported exhaust manifold and panel K&N filter. I highly doubt that those two mods would increase boost level up to 1.5psi.

Anyway, baseline dyno number (first chart) pretty much matched previous dyno number (2nd chart) with Borla header (261whp) in terms of HP, but torque was a little bit off. This may be expected as this map was not designed for ported exhaust manifold.

After correcting AF ratio and tweaking various parameters Chris was able to bring whp up to 282whp level at 19psi tapering off to 16psi at redline.

06/07/06 Protune with ported exhaust manifold:


Protune from April with Borla header:

Last edited by txl146; 06-07-2006 at 09:02 PM.
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Old 06-07-2006, 08:56 PM   #15
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It's important to note that baseline numbers from first chart is done with ported exhaust manifold and K&N panel filter although map was originally made to run with Borla header.

I don't think we can draw any conclusion based on these two charts as there are several variables:

1. Different tuners (previous tuner could never make >262whp even at 22psi).
2. dirty paper filter vs. K&N panel filter (previous tune was done using filthy air filter).

Last edited by txl146; 06-07-2006 at 09:18 PM.
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Old 06-07-2006, 09:05 PM   #16
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so the end numbers were about the same, what about the spool characteristics, peak torque come sooner?
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Old 06-07-2006, 09:20 PM   #17
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It is possible that ported exhaust manifold allowed car to improve low-end torque (~40 wtq @ 3250rpm) and horse power. However, it could also be that tune was more efficient in extracting power out of engine.
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Old 06-07-2006, 10:09 PM   #18
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looks like a better tuen with more boost to me
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Old 06-08-2006, 01:24 AM   #19
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Quote:
Originally Posted by txl146
It is possible that ported exhaust manifold allowed car to improve low-end torque (~40 wtq @ 3250rpm) and horse power. However, it could also be that tune was more efficient in extracting power out of engine.

definitely must be the port job


look at torque at 3k rpms...thats what a pnp'd mani will do for you along with a good tune

+30-40wtg is crazy
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Old 06-08-2006, 01:31 AM   #20
txl146
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Oh, I got my exhaust manifold ported by jdgrimm.
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Old 06-08-2006, 02:41 AM   #21
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Quote:
Originally Posted by txl146
Oh, I got my exhaust manifold ported by jdgrimm.

I've been talking Justin up all over these forums.

There's also a link in the Car parts review thread.
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Old 08-22-2006, 04:45 PM   #22
txl146
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I've received several PM's about my P&P'd exhaust manifold. Here is a bump for those who PM'd me.
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