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Old 09-06-2020, 01:16 AM   #1
Scooby Newbie
Member#: 494651
Join Date: Nov 2018
Question '05 2.5rs exhaust manifold dimensions

I am interested in making my own exhaust headers but I am having trouble trying to figure out where the flange where it mates to the cat is relative to the flanges that mate to the heads. The cat flange seems to be at some odd angle which complicates things further. I can't get a good measurement of any of the dimensions because of the curved pipes and heat shield. I assume subaru made these headers to some spec but I can't find them (nor can apparently any of those ebay sellers who sell headers that don't fit). I am wondering if anyone knows of such a spec and where to find it or has been able to measure the dimensions.
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Old 09-08-2020, 02:19 AM   #2
Scooby Specialist
Member#: 48377
Join Date: Nov 2003
Chapter/Region: MWSOC
Location: "They eat fish soaked in lye"
1996 Gutted, built
XP class Impreza L


It's an internal Subaru spec, and one which they don't share. Best way to do this is bolt everything up and tack weld the flanges to the tubes in place in the chassis with a MIG. Unbolt everything and finish the welds outside of the car. I've done it many times, and always have good result. If I were making 1000 of these I'd do it differently, but for 1 car this method is the easiest.
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