DIY thread- C6 Full exhaust install thread-
 

I'm not really sure why I'm doing this except to help inspire some of you guys to grab a set of tools and jump right in.

My current C6 is an 06 LS2 M6 with -

Vararam CAI
Self ported TB
Smooth Couplers
Bare Essentials Catch can
TR6's
Corsa axle back (actually removed and sold to Bob)


I have serious plans for the car but I am taking it one step at a time. I also just had my 1st child, a little girl (actually 7months old-) and I want to have a car to build and fool around with as she grows up.



This step is really only -

Dynatech C6Z 1 7/8 headers w/off road 3" X pipe (thanks Jeremy @ HPS)
GHL C6Z full 3" axle back (thanks Jeff @ GHL for a smoking deal!!!)

* I would like to appologize to BLOWN ECS ZO6 since I said I was about to buy his C6Z modded axle back but I didn't realize what I had to do to get them to work like factory or even with a M2W swith.

My appologies sir- Bump for your thread :thumbs:

http://forums.corvetteforum.com/c6-p...-2006-z06.html


Anyway, onto a few pics to help you guys since anyone can do this, one bolt at a time.


Looks funny with NO exhaust-

http://i48.photobucket.com/albums/f2...Headers007.jpg

Few more pics "just in case" I ever have a for sale thread and guys want top search for previous pics and condition.

http://i48.photobucket.com/albums/f2...Headers001.jpg
http://i48.photobucket.com/albums/f2...Headers002.jpg
http://i48.photobucket.com/albums/f2...Headers006.jpg
http://i48.photobucket.com/albums/f2...Headers010.jpg


Here is your start-

http://i48.photobucket.com/albums/f2...Headers013.jpg

Pics of the Dynatechs and X pipe-

http://i48.photobucket.com/albums/f2...Headers009.jpg


Here is my LS2 Corsa removed and getting ready to be boxed up for Bob. :thumbs:

http://i48.photobucket.com/albums/f2...Headers008.jpg




Simply remove the plug wires, spark plugs, oil dipstick, catch can (if you have one..Bare Essentials :yesnod:) and the coil packs to allow room for your hands and arms. I also remove the brake booster line to allow room for the rear header bolt. Don't forget to unplg the coil harnes on each side as well as the 02 plug for each manifold.

http://i48.photobucket.com/albums/f2...Headers014.jpg



Be very careful since the alluminum on these cars will cut you, I cut my finger removing the plug wires and this is my 3rd set of C6 LT's to install. Be very careful or there will be blood. I dripped blood all over the place damn it.

Lastly for today, I loosened the header/manifold bolts and sprayed WD40 on them until the next time I remove them, in a day or so.

You can see some blood on the manifold near the fron of the engine.....BE VERY CAREFUL!

http://i48.photobucket.com/albums/f2...Headers015.jpg





I'll update the thread as I go over the next week(s) so you guys can feel comfortable installing these simple parts yourself. I am only doing small ammounts each day so I have ample time with my little one. :thumbs:

I love to follow along in DIY threads w/ good detailed pics! After the headers, you should do another one with an aggressive cam swap to take advantage of the large 1 7/8" headers (no cats) with 3" pipes on that LS2. :thumbs:

BTW-I personally prefer the welds and finish quality of the GHL over the Corsa, good choice.

Thank you sir-

It will get a larger shortblock as well. I can't wait to hear it with the GHL.

Just a little more progress today, just finished removing all of the stock crap. 5 minutes after I got started, it started to lightly rain then 15 minutes into it, down pour with me under the car. Ohwell, had to get done.

Here it is next to the C6Z 3"-

http://i48.photobucket.com/albums/f2...exhaust001.jpg

http://i48.photobucket.com/albums/f2...exhaust002.jpg



As I was getting soaked under the car I thought about the gaskets.. It's not a big deal but the stock GM gaskets are 1 3/4. I never thought about that before so this time, for the hell of it, I am bolting the stock gaskets (best IMHO) to the headers and with my airgrinder, I'm going to open them up to ATLEAST match the Dynatech port (1 7/8). It must account for some power. I bolted the gasket to the header and will grind on the inside of the primary to smooth the welds (Dynatech is smooth but not as smooth as my last set of Kooks) and also open the gasket at the same time. You'll just have to adjuct the gasket for the full range of motion, all the way up, grind, then all the way down and grind.

Anyway, never thought about that before.

http://i48.photobucket.com/albums/f2...exhaust003.jpg

That's about it, Monday I'll have the GHL and I'll post a few pics of the quality out of the box. I should have it all back together next weekend.

The GHL C6Z axle back came in today. I can see straight through the muffler so it may be loud with no cats... :lol:

I will say this, the whole system is very light in weight.

They look great to me. They slip joints are perfect, even into the C6Z mid. I see GHL has been cutting relief tabs into the mufflers so the clamps will bite enough so there is no leak.


See the light...
http://i48.photobucket.com/albums/f2...ySS/GHL008.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL011.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL010.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL003.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL004.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL009.jpg


The welds look just fine IMHO.

http://i48.photobucket.com/albums/f2...ySS/GHL013.jpg

http://i48.photobucket.com/albums/f2...ySS/GHL014.jpg


Finally, my daughter had to get her hands on them when I took them out of the box.

http://i48.photobucket.com/albums/f2...ySS/GHL002.jpg


I should be installing everything this weekend sometime :)

Please let me know when you get done and we can consolidate this into the new DIY sticky I created :cheers:

Great writeup so far. Looking forward to this weekend. :thumbs:

Good call :thumbs:


Jason,

Nice write-up!

Are you planning on getting the new sound on video when you get all this wrapped up?

Thanks,
John

Sure thing :thumbs:

Thank you sir-

Hell yea, should be loud too. I *may* not get it all this weekend but by next week (mid week) I'm sure it will be complete and on the road.

When are you getting your car buttoned up? You were shooting for Christmas right? I am so confused on my cam choice (what's new) and your cam is very close to TSP's Tsunami cam which I was considering so please keep me updated doode.

J

Jeremy @ HPS is the bomb!! Car looks great. Good Luck with it!!!
:cheers:

:iagree:

nice DIY. just for others reading, there is no need to take all the coil packs off and disconnect the brake booster line. i installed mine with no problem at all only removing the plastic engine covers, pulling the plug wires, then removing the spark plugs (so you don't snap it when removing or installing the headers)

other than that, good job!!

Very true, I just like the extra room :thumbs:

How do you get it in that garage? :eek:

Piece by piece :D

J,

I will shoot you a PM with an update

John

Awesome start. I was going to do the same thing, as I am installing mine this weekend. Just waiting for boxes to show up!

http://i55.tinypic.com/2yxkj7b.jpg

Car looks sweet TNT :thumbs:

What are the details in the boxes?

Thanks man! Shocks, end links, UD pulley, 1-3/4 catless headers...you know, that old chestnut ;)

Merry Christmas to me!

Amen sir, Amen.

Sweet mods :thumbs:

The boxes have arrived!


:D

Alraight, today I grinded all the primaries with the gasket's attached. There is a very noticable difference, take a peek-


Here you can see the opened primary vs the standard openeing in the GM gasket.

http://i48.photobucket.com/albums/f2...Headers001.jpg

http://i48.photobucket.com/albums/f2...Headers002.jpg

http://i48.photobucket.com/albums/f2...Headers003.jpg


Anyway, I should have it back together 2morrow :thumbs:

Sweet man, good luck! :thumbs:

Aright......

I'm finished. The Exhaust went on very smooth. The GHL fit better than I would have ever imagined. The Dynatech's obviously fit just fine as well.

Here I need to install the plugs and coils but that leaves plenty of room to work. The headers slide up from the bottom with zero drama but be sure to disconnect the battery since the pass side header comes very close to the starter/wires. Don't forget 24" LS2 02 extensions :)

Nook and Tranny has them for $40 bones-

I personally tighten the header bolts from the center working out to the ends but with these thick flanges, it probably doesn't matter. Stock bolts and GM gaskets. Just leave everything lose until you're finished and then tighten it keeping everything straight.

http://i48.photobucket.com/albums/f2...ustdone004.jpg

http://i48.photobucket.com/albums/f2...ustdone018.jpg

The tips are HUGE on the car. Sitting on the ground in the garage, they didn't seem that big.

http://i48.photobucket.com/albums/f2...ustdone005.jpg

http://i48.photobucket.com/albums/f2...ustdone006.jpg

Rear shots GHL installed .... LOTS of room and LOTS of weight removed. Use lots of WD40 on the rubber hangers or you can use Royal Purple Syncromax to slide the muffler hangers in easily. :)

http://i48.photobucket.com/albums/f2...ustdone007.jpg

http://i48.photobucket.com/albums/f2...ustdone008.jpg

http://i48.photobucket.com/albums/f2...ustdone009.jpg

http://i48.photobucket.com/albums/f2...ustdone010.jpg

Over the IRS pipes...tons of room there too-
The axle pipes slide right up from the bottom to the rear with ZERO drama, thought I was doing something wrong it was so easy..



http://i48.photobucket.com/albums/f2...ustdone015.jpg

http://i48.photobucket.com/albums/f2...ustdone014.jpg

http://i48.photobucket.com/albums/f2...ustdone011.jpg

On the ground-

http://i48.photobucket.com/albums/f2...ustdone017.jpg

http://i48.photobucket.com/albums/f2...ustdone016.jpg

Last step-

Who knows what's missing from this picture? One single item, anyone notice it??

http://i48.photobucket.com/albums/f2...ustdone019.jpg

Now for my review-

It sounded like Jesus himself was returning when I started it. This is BY FAR the loudest car I've had. I will get vids tomorrow but it is loud. There is little drone and it sounds amazing under WOT.

Now I need to find a vendor who is running a good mail order tune special. Anyone know of a cheap one..? I am really out of money. :D


Vids will be up tomorrow but expect to have your speakers blown, I hope I don't go to jail-

Serriously- :yesnod:

Next round of mods-

FAST 102 (will port when I decide on heads so they match )
UD pulley
Cam (no idea yet....)
Springs (Patriots that I already have)
Push rods
YT's
Heads (TEA, AFR or TF's)
102 TB

Speed Density tune

Then-

A 402-427 when the money comes :thumbs:

ECS does mail order tunes, and I think they have a deal for like $150 during the winter. Give Chris a call:cheers:

Where's the dipstick? Lol

I had to pull my starter to get mine in. Buddy cross threaded a header bolt into the passenger head and put the project behind a day.

Good stuff, Jay. Well have to compare when I wrap mine up Sunday.

-Ronnie

DAMN! Good call Ronnie :thumbs:

Good luck, post up some pics if you get chance man, Merry Christmas

I would like to know a list of the tools you used.
what size sockets, how long of an extension you needed for the socket wrench?
Also how high off the ground did you have to have the car to be able to put the headers on from under it?

No problem

3/8 drive for most here

13mm for the header bolts (deep and short socket) and midpipe hanger bolts.

15mm (deep) for the exhaust bolts (pretty much everywhere)

1 basic 6 inch extension

Spark plug socket

7/8 wrench for the 02's (IIRC)

15mm (short) for the oil dipstick bolt

10mm (deep 1/4 drive and socket to clear alternator) for the coil removal bolts (if you choose)

Another important part is an EXTRA extension with a 17mm or larger socket to use for leverage on the ratchet. Put the 17mm socket ove the ratchet (with the extension inserted) and use to break loose or when securing the big exhaust clamps.

I will measure the (2) jackstands in the 3rd position- 18" total is all I needed for the whole job as well as a floor jack.

Also need WD40 to ease removal of exhaust from the rubber mounts, trust me, I used Royal Purple actually.

Other items you'll need-

Zip ties for securing the 02 extension wires OFF the exhaust
Wood for jacking under the alluminum


Damn, I think thats about it.... :flag:

For the record, if anyone is near Fort Lauderdale/Tamarac and needs a set installed and can leave the car for a weekend, I'll do it really reasonably, I'll even take progress pics along the way. Just throwing that out there. :thumbs:

Nice going Jason, we want video!!!! :lol:

Jaykay,

Did you mean 3/8" drive? Just making sure the person who asked doesn't try to get 3/4" drive sockets for this job.
Also would be a good idea to use some anti-seize on the threads, specially in the heads.


Nice Write up,
DJ

I forgot to say thank you-

I will look into that, thanks :thumbs:

Dude, I'm paranoid to start the car. I came home today ideling in 3rd to keep it quiet.

I'll have a few good vids tomorrow though, Merry Christmas to you and your family John. :flag:

You are correct sir, all the 1 7/8 vs 1 3/4 threads have tainted my fingers. I'll edit it, thank you- :thumbs:

Must be pretty rowdy, bet it sounds bad a$$!!

Thanks man, hope you and your family are having a great Holiday!

John

Great thread! :cheers: I love the how to threads.

You think it's loud now...wait until you get a cam.:eek: Multiply the sound by 150%. I had Magnaflow 14336 mufflers that look like yours, I had to go back to stock mufflers and added QTP cutouts for when I want it loud. But I'm getting to be an old man I guess, so perhaps my taste for loud has changed. :lol:

Damn it, this is a terrible video.

I'll have to do it over some time this week. I shot (3) videos but the sound only works on the 1st one and it was really windy today. Ohwell, don't judge it here but since I went through the trouble, I'm posting it anyway.

I'll have a better longer one later this week...damn it.

http://s48.photobucket.com/albums/f2...haust001-1.mp4

Sounds good, seems like it is missing...........a larger cam! :lol: j/k

Car looks great, love the color combo and the wheels set it off!

:cheers:

John

Finished mine today...finally!

It's...quiet! But it sounds evil and it picked up a lot of midrange power. Those Callaway DD's really keep the db levels down.

The OBX LTs fit perfect and seem to work fantastic.

ahh OBX, nice. Did you need o2 extensions? did you through any codes? Does it come with cats or are they hollow pipe that look like cats?
Thanks

Thanks John, I'll have a good video some time this eek. I'm getting used to it though, my ife took it around the block so I could determine how loud it is on a scale of 1-10 and it's a 9-9.5.


Good job dude! The OBX look good too-

My "W" key is acting up- :rolleyes:

Great write up man! This will really help me when time comes to install my headers. :thumb:

Very nice write up. :thumbs::thumbs:

:iagree: great pics

Oh yeah. I got my car back and it mysteriously got louder after the cam!!! Dang!! Before I used to cruise with my Fusions open ALL the time, only closing them when my GF got in the car. Now, I find myself closing them more often!!! :D :thumbs:

Revival of old, but just doing headers myself. Removing factory exhaust didn't take too long, probably 2.5 hours going slow. I did grind the weld off the factory clamps on the h-pipe to muffler section so I could reuse them. Factory header bolts were stupid hard, some kind of sealer or loctite on them. Driver side rear bolt was easier access from the bottom. New stuff going in tomorrow, so I'll update if there's anything else that might help.

BTW, the stainless steel American Racing entire exhaust weighs about as much as one of the factory manifolds.

Finished up today. Installed O2 sensors and extensions before starting. Had to use a oxygen sensor socket to remove from factory manifold. Passenger header went in easy, only had to disconnect sensor on oil pan and slid right in. Went in so easy, I had to think if it was right. I have an auto and it hit the trans lines. Left header bolts slightly loose so they were a little adjustable (highly recommended). Started from rear moving forward, muffler pipes went in smoothly, x-pipe was easy (header bolts were loose). O2 sensor connectors had to be moved slightly because I used 12" instead of 24". I'd recommend 24" if you want the connector to sit in the factory spot. Started her up with NPP exhaust closed and it was slightly louder than factory, but not much. Opened up the exhaust and it's really loud! Surprised it was such a huge difference.

Now for the bugs and do overs. First I tightened all the header bolts and tried to put the xpipe on. No go. Would fit upside down (o2 sensors facing down) but not the correct way. So I'm thinking...maybe it's right? Driver side piece to muffler was too short that way. So unbolt everything and try xpipe again. I swear the xpipe was bent out of shape or something how easy it would fit upside down but not the correct way. A bit of time and lots of frustration later, I googled instructions (bought a used set of ARH). Said start from muffler pieces and work forward with HEADER BOLTS LOOSE. Dammit, did I want to loosen those things again? Yeah, if this was going in, I was. Smooth as pie after that. Used a rubber mallet to help persuaded joints together. Screwdriver to bend trans lines that touched.

Side note, people have asked how high you need to jack it up. My jacks measured 14" up front and 13" in the back. I'm a little guy so that was plenty for me. Overall time including screw-ups was roughly 7 hours.