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Old 10-16-2012, 11:29 AM   #1
blk6s
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Default RalliSport 2.0i UEL Header build...

Here's a "pre-prototype" header I made for the 12/13 2.0i
I'll update with some specifics later.








1 5/8" primaries
Fully blended merge bullet
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Old 10-16-2012, 12:00 PM   #2
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Nice work, as usual What the big differences, if any btwn the FB20 and the EJ253 stud spacing wise? It appears that the layout is fairly similar from the prototype.
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Old 10-16-2012, 02:59 PM   #3
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Oooooooohhhhh......Aaaaaaahhhhhh! Grasshopper is patiently waiting for this.

Last edited by uspopo; 10-16-2012 at 03:04 PM.
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Old 10-16-2012, 04:51 PM   #4
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Quote:
Originally Posted by blk6s
Here's a "pre-prototype" header I made for the 12/13 2.0i
I'll update with some specifics later.

1 5/8" primaries
Fully blended merge bullet
Please shoot a video when you try it out. Excited to hear the sound.
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Old 10-16-2012, 08:04 PM   #5
wavear15
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In on 1. Yes I want.
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Old 10-16-2012, 09:32 PM   #6
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Dammnnnnnn these look awesome!

Will you be considering doing a dyno run for stock vs your exhaust setup for comparison?

Last edited by Wes_888; 10-16-2012 at 09:32 PM. Reason: typo
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Old 10-17-2012, 12:08 AM   #7
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Quote:
Originally Posted by GEE-OTTO View Post
Nice work, as usual What the big differences, if any btwn the FB20 and the EJ253 stud spacing wise? It appears that the layout is fairly similar from the prototype.
The dual port flanges I have made for the 2.5i fit perfectly on the FB20. The overall distance from one side to the other seems to have increased by 1-2mm. What's odd is that it almost appears that whoever designed the factory exhaust manifold didn't take this into account, as my factory unit was pinched too tight and had to be pried on and off. It started to booger up the threads on the engine studs, which I wasn't very excited about.

The bolt circle diameter on the three bolt flange has been increased (which is why I had to hack up one of my off the self 2.5i flanges to make it fit, until I get some custom ones made). Also, the angle of attack of the three bolt flange is slightly different: on the 2.5i its roughly 15 degrees from being perpendicular with the engine, on the FB20 its only about 5 degrees.

Quote:
Originally Posted by MjSub2.0 View Post
Please shoot a video when you try it out. Excited to hear the sound.
I'll replace the factory mid pipe (and pancake resonator) with a custom mid pipe first. I wasn't too impressed by the rumble with just an axleback.



To all those seeking rumble for their 2.0i PLEASE NOTE:

I'm not trying to turn away sales, but since the 2.0i already comes with that wonky "Lakester" style collector, it's inherently a UEL design and you can gain at least a mini rumble by simply bolting on an axleback or full catback (both of which I'm also developing). So spending $600 on a aftermarket UEL just to gain a little more rumble seems redundant and pricey, (but hey, if there is enough demand, I'm more than willing to make one for that purpose!). Therefore, I will be concentrating on building a performance header while still retaining a UEL design (to satisfy the demand for rumble). The header I posted pics of is simply a starting point, I can lean more toward the peak hp side or toward the lower end tq side. I can stay 4-1 or go 4-2-1, experiment with piping diameter and lengths etc etc. Honestly though, I mostly put this header together to see how long I can run a HFC on a PZEV model before it throws a cel.

Quote:
Originally Posted by Wes_888 View Post
Dammnnnnnn these look awesome!

Will you be considering doing a dyno run for stock vs your exhaust setup for comparison?
Absolutely! My goal is to come up with a header/cat delete pipe/catback combo that reclaims the 20chp the base Impreza lost when going from the EJ253 to the FB20. Hey, its good to have goals...

Last edited by blk6s; 10-17-2012 at 12:45 AM.
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Old 10-17-2012, 12:20 AM   #8
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Sweet, this looks awesome. I'm interested in one too.
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Old 10-17-2012, 04:07 AM   #9
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Sweet! Thanks brother..=)
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Old 10-17-2012, 08:02 AM   #10
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Looks good, I thought I heard a slight rumble when I watched a video of someone revving with an unbolted muffler
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Old 10-17-2012, 09:29 AM   #11
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Mike any pics of a stock 2.0i manifold off the car ??
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Old 10-17-2012, 10:37 AM   #12
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Quote:
Originally Posted by GEE-OTTO View Post
Mike any pics of a stock 2.0i manifold off the car ??




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Old 10-17-2012, 10:47 AM   #13
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I am grateful that you purchased an Impreza so that you have a fulltime vehicle at your disposal for R&D. Thank you sir.
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Old 10-17-2012, 02:29 PM   #14
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I got a custom cat back and yes it has a little rumble, but I want more lol!
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Old 10-17-2012, 04:47 PM   #15
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Interesting headers they changed to
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Old 10-17-2012, 08:58 PM   #16
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How do you feel about an EL design with the same collector and no cat? Any ballpark on what the price would be? I may be interested in such a header if it fits the BRZ. I could even calculate the primary diameter and lengths. I would love to make my own header but I don't have a tig machine and you seen to have it figured out.
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Old 10-18-2012, 03:50 AM   #17
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Quote:
Originally Posted by uspopo View Post
I am grateful that you purchased an Impreza so that you have a fulltime vehicle at your disposal for R&D. Thank you sir.
Absolutely, my pleasure.

Quote:
Originally Posted by MjSub2.0 View Post
I got a custom cat back and yes it has a little rumble, but I want more lol!
Consider it done. I'll build a 4-2-1 prototype for those more interested in rumble than power gain.

Quote:
Originally Posted by RaceFaceXC View Post
How do you feel about an EL design with the same collector and no cat? Any ballpark on what the price would be? I may be interested in such a header if it fits the BRZ. I could even calculate the primary diameter and lengths. I would love to make my own header but I don't have a tig machine and you seen to have it figured out.
Now this proposal excites me. I would love to tackle such a project. Price depends on a number of factors, but the million dollar question is will a header designed to fit the FB20 fit the FA20? I personally have wondered this very thing but haven't had the time to look into it. Assuming you own a BRZ, does your FA20 factory exhaust manifold look identical to the FB20 exhaust manifold pictured above? Any info you could provide would be extremely beneficial. Thanks
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Old 10-18-2012, 06:15 AM   #18
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I'm primarily interested in power gains but I would like the headers to make the rumble louder too. That would be the best of both worlds.
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Old 10-18-2012, 08:55 AM   #19
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Quote:
Originally Posted by blk6s

Absolutely, my pleasure.

Consider it done. I'll build a 4-2-1 prototype for those more interested in rumble than power gain.

Now this proposal excites me. I would love to tackle such a project. Price depends on a number of factors, but the million dollar question is will a header designed to fit the FB20 fit the FA20? I personally have wondered this very thing but haven't had the time to look into it. Assuming you own a BRZ, does your FA20 factory exhaust manifold look identical to the FB20 exhaust manifold pictured above? Any info you could provide would be extremely beneficial. Thanks
I don not own one. A customer of mine is a Subaru enthusiast, also, and he said he had one coming and has big plans for it. We were talking about the lack of aftermarket parts for the BRZ and headers were the most critical for getting the power bumped up. I'll ask Crawford if they have any pics of the manifold from their BRZ that they turbo'd. If I get one I'll link to it here.
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Old 10-18-2012, 11:36 AM   #20
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Quote:
Originally Posted by pkL
I'm primarily interested in power gains but I would like the headers to make the rumble louder too. That would be the best of both worlds.
I agree
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Old 10-18-2012, 05:12 PM   #21
blk6s
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Quote:
Originally Posted by RaceFaceXC View Post
I don not own one. A customer of mine is a Subaru enthusiast, also, and he said he had one coming and has big plans for it. We were talking about the lack of aftermarket parts for the BRZ and headers were the most critical for getting the power bumped up. I'll ask Crawford if they have any pics of the manifold from their BRZ that they turbo'd. If I get one I'll link to it here.
A quick google search during lunch proved fruitful, looks like Perrin is developing exactly what you seek: http://blog.perrinperformance.com/br...n-and-proving/

AP has makes a 4-2-1 EL header for the BRZ as well.
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Old 10-18-2012, 05:20 PM   #22
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The stock Brz headers actually look pretty good to begin with
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Old 10-18-2012, 05:28 PM   #23
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Well I bought your first one and I LOVE IT
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Old 10-19-2012, 03:22 AM   #24
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Well I bought your first one and I LOVE IT
How much did it come up to?
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Old 10-19-2012, 10:15 AM   #25
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Quote:
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How much did it come up to?
He was actually referring to my original UEL header for the 2.5i
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