Kooks Headers & Magnaflow cat-back

[jnrandall]

Picked up headers for RonsV and myself on Friday from Kooks. We planned to install mine on Saturday and his on Monday. I have the Magnaflow exhaust on my LS6 and Ron has the Corsa with his LS2. I was very clear when I ordered the headers and each of the multiple times I called them back to clarify other issues, i.e. bung weld for tune, Jet hot coating questions (didn't get it), etc.

Saturday morning, Ron and I downloaded the install instructions from CadiFAQ and started my car. I was quite surprised that instructions were not included. Several hours later, after installing the headers, we started to hook up the Magnaflow. Bolted on the cats extention to the headers -> lifted the Magnaflow, IT DOESN'T FIT.

Perhaps Kooks failed to mention that the Magnaflow would need to be cut to fit. Perhaps Kooks gave me the wrong part. In any event, countless hours were invested, my car was apart, I was 30 miles from home, Kook was closed until Tuesday, and all local shops were closed. Ron pulls out the Sawzall and cuts the exhaust. A few hours after that, had issues hooking up the passenger side O2 pre-cat sensor. Eventually we got it.

Hooked everything up, torqed the bolts, closed the hood and fired her up.

It works and no check engine light!

Sunday, 2AM - I drive home. :bigD:

My body still hurts. I look forward to an easier LS2 install next week!

Conclusion, personal observations and thoughts:

If you have anything other that a stock exhaust or Corsa, triple ask about the extentions and then recheck 15 more times with Kooks.

Never attempt a job like this without someone who knows what to do, how to do it and has every tool imaginable in their home garage. (THANKS RON!)

Change spark plugs (I used Bosch Platinum +4) while you're there

Use dielectric grease and anti-seize compounds where necessary. You'll be happy you did the next time you take wrench to bolt.

Check and recheck all connections. Also torq bolts as necessary.

Install all O2 sensors (pre and post cat) before you actually install the headers.

Make certain the wiring near the headers aren't touching. Add more automotive heat shielding on the wiring near the headers too.

I can't think of anything else right now, but I'm sure more will come to me later. Drove the ol' girl today and she sounds and feels awesome. Also, no check engine light. I had 2 seperate prasies from other motorists today on how sweet my V sounds.

After we complete Ron's V, we're off to Cartek for the tunes.

Perhaps they'll be a cam for me by Springs end.

Vroooommmmmmm!

[ctsvflorida]

Jesse, Jesse, Jesse. You should have contacted me about the Kooks deal or maybe you didn't remember that I have them too! I knew that it did not bolt up to your cats and if used their cats then they don't work either without modifying. I had them install mine and they made their prototype x-pipe for mine and said it was the first magnaflow they did. Anyway, if you wanna just call me and I can explain more and I am also wondering how much you paid. If so, then PM your number again and I'll call you.

P.S. I told you it sounds great though right?

[JOEYCTS-V]

He's hooked! I see heads and cam in the future! I gotta check it out at Captree next time.

[Ronsv]

Hey Jessie, Glad to hear that you are enjoying your headers. Welcome to Mod Hell, as I said, won’t be long until you will be itching for a Maggie or a cam and heads, better still how about both!

Just a few things to share with my fellow forum members on the header install:

#1 Basically it’s a straightforward install, hardest part is pulling the boots off the plugs, have a nice plug pulling tool with decent leverage, be sure to only pull on the boot, but you already knew that! No biggie this part of the install, if you work on engines you’ll know what to do, just take your time so you don’t cut your hands up.

#2 VERY IMPORTANT, Be sure to check the clearance between the headers and several wire looms, one loom on the drivers side and one on the passenger side were resting on the headers. You will need to use wire ties to pull these looms off of the headers, still the clearance is very close, about a ½ inch at most. I would rap those babies well with heat resistant tape, or wrap.

#3 By all means, hook-up the pre cat O2 extension on the passenger side BEFORE you put the header on, close to impossible to reach otherwise. Had Jessie push down on the top of the connector with a long screwdriver from the top of the engine, (no way to reach down) while I pushed up on the connecter from the bottom. Trust me; don’t forget to put the extension on before you bolt up the header!

Other than these 3 “TIPS” this is a typical header install.
The Kooks headers were very nicely finished, with all welding flash grinded away nicely on the inside of the flanges. These headers are not cheap, but they are well tuned and seem to make good power.

Oh yea, if you have a Magnaflow exhaust, be sure to ask the kooks guys what their definition of “simply bolt on” is. Be sure so have a nice sharp blade on hand for your sawsall!

[CTS-BV]

Originally Posted by ctsvflorida

Jesse, Jesse, Jesse. You should have contacted me about the Kooks deal or maybe you didn't remember that I have them too! I knew that it did not bolt up to your cats and if used their cats then they don't work either without modifying. I had them install mine and they made their prototype x-pipe for mine and said it was the first magnaflow they did. Anyway, if you wanna just call me and I can explain more and I am also wondering how much you paid. If so, then PM your number again and I'll call you.

P.S. I told you it sounds great though right?

I've been in contact with Tbyrne Motorsports. I've been considering their Jethot 2000 coated Kooks headers with CATS to mate to my Magnaflow exhaust. Are you saying that these don't mount right, right out of the box? If that's true then Kooks didn't do their homework on these headers and make them right for our cars. I wonder if these were originally designed for another LSX driven car and "made" to "sort of" work with our V's.

Any thoughts? I am interested to know.

CTS-BV

[Ronsv]

CTS BV, the headers mount-up fine, the fit is very good. It is the connection pipes that did not hook-up easily, with a little cutting and “convincing” we were able to make it work. The connection pipes that Jessie got were labeled “factory exhaust”.

[ctsvflorida]

Originally Posted by CTS-BV

I've been in contact with Tbyrne Motorsports. I've been considering their Jethot 2000 coated Kooks headers with CATS to mate to my Magnaflow exhaust. Are you saying that these don't mount right, right out of the box? If that's true then Kooks didn't do their homework on these headers and make them right for our cars. I wonder if these were originally designed for another LSX driven car and "made" to "sort of" work with our V's.

Any thoughts? I am interested to know.

CTS-BV

I spoke to Jesse on the phone and what Ron said is what happened. The 'retard', who Jesse had the misfortune of dealing with, gave him the wrong connection pipes or it would have been much easier, as Ron can tell ya!

RON: Consider tuning at Vette DR's! It is closer, cheaper and Cartechs tune can't be better, only equal! Maybe Cartech will appear to be a nicer guy but Carmen, seems to be a nice guy, just not very talkative! I have heard many complaints about his attitude but never a bad word about their tunes or work! Again, seemed like a nice guy to me but definitely, to the point and seems like he doesn't have much time to talk to you or anyone else! I think it's kinda funny! I spoke to Jesse about this so he can tell you more!
Later

[CTS-BV]

Originally Posted by Ronsv

CTS BV, the headers mount-up fine, the fit is very good. It is the connection pipes that did not hook-up easily, with a little cutting and “convincing” we were able to make it work. The connection pipes that Jessie got were labeled “factory exhaust”.

If I implied that the headers might not fit to the heads properly, then I miscommunicated. The questionable fitment I was referring to was the junction to the CATS and, ultimately, to the Magnaflow exhaust. I believe ordinary C5 headers will fit on the 04 V's (LS6) just fine. I believe all the accessories are in the same places. The more difficult area to accommodate is after the collectors of the headers where it meets the rest of the exhaust. That's where a good header company makes people happy so that any person can install them without a sawzall or other tools than some wrenches.

Now, is this the case? Is there a reliable kit from Tbyrne or Kooks directly or ?? that will allow we, who should not have to use cutting tools to install those great headers?

CTS-BV

[Ronsv]

Hey Paul (ctsvflorida), a few years ago I spent some time talking to Carmen while in the staging lanes between ¼ mile runs at Raceway Park, I was running my Vette at one of the Vette days.
Carmen does seem like a decent guy, just not very outgoing and talkative, a quiet type of guy. Maybe I’ll reconsider, they are a bunch closer and it's a lot nicer than dealing with bridge traffic!

[Ronsv]

Originally Posted by CTS-BV

If I implied that the headers might not fit to the heads properly, then I miscommunicated. The questionable fitment I was referring to was the junction to the CATS and, ultimately, to the Magnaflow exhaust. I believe ordinary C5 headers will fit on the 04 V's (LS6) just fine. I believe all the accessories are in the same places. The more difficult area to accommodate is after the collectors of the headers where it meets the rest of the exhaust. That's where a good header company makes people happy so that any person can install them without a sawzall or other tools than some wrenches.

Now, is this the case? Is there a reliable kit from Tbyrne or Kooks directly or ?? that will allow we, who should not have to use cutting tools to install those great headers?

CTS-BV

CTS-BV, Kooks does sell 2 application specific connection pipes, they have one for the factory exhaust and they have one for a corsa exhaust. I’ll let you know how they fit when I slap the headers on my LS2 corsa equipped car. After seeing how close the pipes come to some of the wire looms, I think I am going to send my headers off to JetHot for a ceramic coating. I have had 2 other sets of headers coated by JetHot and it is a quality coating, should help with the heat a little, sure can’t hurt. Soon as I get the headers bolted up, I let you know about the fit!

[CTS-BV]

Originally Posted by Ronsv

CTS-BV, Kooks does sell 2 application specific connection pipes, they have one for the factory exhaust and they have one for a corsa exhaust. I’ll let you know how they fit when I slap the headers on my LS2 corsa equipped car. After seeing how close the pipes come to some of the wire looms, I think I am going to send my headers off to JetHot for a ceramic coating. I have had 2 other sets of headers coated by JetHot and it is a quality coating, should help with the heat a little, sure can’t hurt. Soon as I get the headers bolted up, I let you know about the fit!

Awesome! Please post pics from underneath too!

Keep in mind that ceramic coatings aid in lowering outer temps, but you still need to take special care in tying back all your wiring as if you had no coating at all.

Good luck!


CTS-BV

[rand49er]

Originally Posted by Ronsv

CTS-BV, Kooks does sell 2 application specific connection pipes, they have one for the factory exhaust and they have one for a corsa exhaust. I’ll let you know how they fit when I slap the headers on my LS2 corsa equipped car. After seeing how close the pipes come to some of the wire looms, I think I am going to send my headers off to JetHot for a ceramic coating. I have had 2 other sets of headers coated by JetHot and it is a quality coating, should help with the heat a little, sure can’t hurt. Soon as I get the headers bolted up, I let you know about the fit!

Glad you guys like the sound ... ain't it sweet?

Ron, when you install your Kooks, if you haven't already, seriously consider dropping your Corsa down front to rear. I had the Corsa already installed and got lazy; I just dropped the front, and it was a huge PITA to get the Corsa to back up far enough while on its hangers to get it to connect up.

Also, I'm not surprised that Kooks people sort of glossed over the mating up glitch with the Magnaflow. The guy I talked to there seemed to anticipate my questions and gave me decent advice. I think some people assume we ALL have basically a fully equipped Tuffy Muffler garage connected to our houses, only with a lawnmower in the corner.

[Ronsv]

Originally Posted by rand49er

Glad you guys like the sound ... ain't it sweet?

Ron, when you install your Kooks, if you haven't already, seriously consider dropping your Corsa down front to rear. I had the Corsa already installed and got lazy; I just dropped the front, and it was a huge PITA to get the Corsa to back up far enough while on its hangers to get it to connect up.

Also, I'm not surprised that Kooks people sort of glossed over the mating up glitch with the Magnaflow. The guy I talked to there seemed to anticipate my questions and gave me decent advice. I think some people assume we ALL have basically a fully equipped Tuffy Muffler garage connected to our houses, only with a lawnmower in the corner.

Thanks for the tip, I could see that the exhaust will not shift backwards much while suspended by the rear hangers. In addition when the exhaust pivots down, the exhaust tips will push up against the rear bumper cover, probably better to avoid that. No biggie to pull the mufflers off of the hangers.

I will post a few pics’ when done, and yes, it is true that the wire looms still need to be as far away form the headers as possible, even with the ceramic coating!

[rand49er]

Originally Posted by Ronsv

... it is true that the wire looms still need to be as far away form the headers as possible, even with the ceramic coating!

I just ty-wrapped mine away as far as I could. With my style of driving, the airflow should be enough to keep 'em from fryin'.

[HushH]

Ron,

I don't know if it's feasible, but I'd love to hear clips of your LS2 with Corsa before and after the Kooks.