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Old 08-24-2013, 06:54 PM   #1
blk6s
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Default RalliSport EL 4-1 2.5i header

Quick peek at a custom build I just completed for a very patient customer.

1 5/8" primaries
4-1 merge collector
EL to the valves (+/- 1")
OEM grade high flow cat







And yes, I will be offering these for sale (along with their UEL 4-1 counterpart).
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Last edited by blk6s; 08-26-2013 at 03:37 PM.
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Old 08-25-2013, 01:52 AM   #2
subi400
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That looks sweet....

The boxer rumble might be lost using this header but the power and response will be worth it!

I like the fact you are using a 3 bolt flange right after the cat to create a tighter seal. What brand of 3-bolt flange? Is that a 2.25" collector?

~Josh
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Old 08-25-2013, 07:48 AM   #3
GrundleJuice
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That header makes my pants tighter. How much time went into that collector?
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Old 08-25-2013, 01:54 PM   #4
iommichild
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I'm so f'n stoked to get this baby installed...!
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Old 08-25-2013, 04:52 PM   #5
Ivan MR
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Wow those are good looking!!! How much are they and how do I place a order for a set of those headers??
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Old 08-25-2013, 05:02 PM   #6
Fender137
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What material was used to make the header?
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Old 08-26-2013, 11:01 AM   #7
Kevin Thomas
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Looks very nice!
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Old 08-26-2013, 03:52 PM   #8
blk6s
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Quote:
Originally Posted by subi400 View Post
That looks sweet....

The boxer rumble might be lost using this header but the power and response will be worth it!

I like the fact you are using a 3 bolt flange right after the cat to create a tighter seal. What brand of 3-bolt flange? Is that a 2.25" collector?

~Josh
The flanges I have water jet cut to my specs. Correct: 2.25" collector (I should have included that in the description).

Quote:
Originally Posted by RaceFaceXC View Post
That header makes my pants tighter. How much time went into that collector?
My gf just happened to look over when I was reading this and noticed the tighter pants comment and asked "do guys actually talk like that about car stuff??" My answer was "yes, yes they do."

My time into the collector was the time it took me to order it from my supplier. I normally go with a formed collector and fab up an internal merge bullet, but in this case I decided to go with a premade collector. The extra cost was outweighed by the time savings and quality of the product.

Quote:
Originally Posted by iommichild View Post
I'm so f'n stoked to get this baby installed...!
Tracking info sent, thanks!

Quote:
Originally Posted by Ivan MR View Post
Wow those are good looking!!! How much are they and how do I place a order for a set of those headers??
pm'ed you back. I'll update my website sometime in the near future.

Quote:
Originally Posted by Fender137 View Post
What material was used to make the header?
I work exclusively with 304ss (the cat is from Magnaflow and is 409ss).

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Originally Posted by Kevin Thomas View Post
Looks very nice!
Well thank you!
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Old 08-26-2013, 06:26 PM   #9
GrundleJuice
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I know burns makes a very nice merge collector but it's Texa$.
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Old 08-26-2013, 11:20 PM   #10
GEE-OTTO
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As always nice work man!
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Old 08-27-2013, 03:35 PM   #11
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Purdy.

I like it. Primary and secondary sizing is good. From what I've figured long ago, the primaries could be longer for the stock cams, why TWE's header is as twisty as it is, but shorter primaries like yours may fit better with anyone running sport cams and a little higher torque band.
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Old 08-27-2013, 08:16 PM   #12
blk6s
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Quote:
Originally Posted by RaceFaceXC View Post
I know burns makes a very nice merge collector but it's Texa$.
I believe the merge collectors are made in house by my supplier, but I do know their formed collectors are sourced from Cone Engineering. I've used literally hundreds of formed collectors from Cone with no problems, although it is a bit of a PITA to order from them directly.

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Originally Posted by GEE-OTTO View Post
As always nice work man!
Thanks. You've watched me come a long way from making cat pipes on the side, just for fun.

Quote:
Originally Posted by Back Road Runner View Post
Purdy.

I like it. Primary and secondary sizing is good. From what I've figured long ago, the primaries could be longer for the stock cams, why TWE's header is as twisty as it is, but shorter primaries like yours may fit better with anyone running sport cams and a little higher torque band.
Larger primaries raise peak torque, while lengthening the primaries raises the curve before peak torque is made (at the expense of having it roll off quicker after peak torque).

The "twisty" header that TWE makes is for the pre-06 2.5i (I believe that some have fitted them on the 06+ 2.5i but with some minor interference).

The reason the primaries on my EL header are relatively short is simple: there just isn't enough room to make them longer and still retain the factory mounting location for the cat pipe. Case in point: TWE actually makes a 06+ 2.5i specific EL header and it looks extremely similar to mine



This is no coincidence, as there is really only one logical setup that works.
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Old 08-28-2013, 06:04 AM   #13
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That's right, diameter places the pivot point, length tilts the curve.
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Old 08-29-2013, 08:03 AM   #14
Distant.Calling
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Hopefully we can see dyno figures. Just curious what the power difference is between this EL and UEL.
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Old 08-30-2013, 11:28 AM   #15
tiger2011
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Looks beautiful. Very much do want.
Would love to see the dyno charts on these too!
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Old 08-31-2013, 03:16 PM   #16
iommichild
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Initial butt-dyno says - theres def more grunt in the 2800 - up range...When flooring the throttle, it feels less "weeeeeee" and more "woooooooo" if that makes sense? Like the difference between a yelp and a bellow. (weird way to describe, I know..)

My hope is to get it tuned at FTW here within the next month. I'll definitely post results.

Thanks again Mike - beautiful product, fits perfectly and is veerrrry nice!
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Old 08-31-2013, 06:20 PM   #17
Distant.Calling
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So CEL's so far?
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Old 08-31-2013, 06:30 PM   #18
kevwill
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i want these, keep me updated on price and dyno results. When do you plan to start production, groupe buys,?????
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Old 09-01-2013, 12:26 AM   #19
iommichild
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No CELs at all. Haven't experienced a 'cold start' yet though since its still muggy and hot here in the Willamette Valley.
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Old 09-02-2013, 10:55 AM   #20
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Quote:
Originally Posted by Distant.Calling View Post
Hopefully we can see dyno figures. Just curious what the power difference is between this EL and UEL.
Quote:
Originally Posted by tiger2011 View Post
Looks beautiful. Very much do want.
Would love to see the dyno charts on these too!
I doubt I'll have time to dyno test a new set until this winter.

Quote:
Originally Posted by kevwill View Post
i want these, keep me updated on price and dyno results. When do you plan to start production, groupe buys,?????
I'll try to update my website when I have the chance. I'm thinking about offering them with a metallic substrate cat for maximum flow, or with a OEM grade cat for those worried about throwing a cel.
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Old 09-02-2013, 04:27 PM   #21
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Quote:
Originally Posted by RalliSport Racing View Post
I'm thinking about offering them with a metallic substrate cat for maximum flow, or with a OEM grade cat for those worried about throwing a cel.
Would you consider offering these with a cat delete option?
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Old 09-02-2013, 04:39 PM   #22
RalliSport Racing
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Would you consider offering these with a cat delete option?
Sure thing
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Old 09-06-2013, 08:31 AM   #24
N/A_Scoobs
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Whats the horse power gains for this EL version please
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Old 09-06-2013, 09:04 PM   #25
RalliSport Racing
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Quote:
Originally Posted by iommichild View Post
Initial butt-dyno says - theres def more grunt in the 2800 - up range...When flooring the throttle, it feels less "weeeeeee" and more "woooooooo" if that makes sense? Like the difference between a yelp and a bellow. (weird way to describe, I know..)

My hope is to get it tuned at FTW here within the next month. I'll definitely post results.

Thanks again Mike - beautiful product, fits perfectly and is veerrrry nice!
Glad you like it. Now the bottle neck in your exhaust is the factory cat pipe, which pinches down to 2" right after the header. You might want to address that if you haven't already. I make HFC pipes, but haven't had time to update my website yet. If you do need one, email me and I'll hook you up with a discount.

Quote:
Originally Posted by N/A_Scoobs View Post
Whats the horse power gains for this EL version please
I won't know until I dyno test them against the factory header, which won't be until winter.
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