NeoTokyo

The stock 94-98 Shorties aren't quite as good as true aftermarket but the difference is too close to warrant spending the money unless you go SC or use a STS turbo system (Turbo at rear of car, don't have to get special manifolds.)

The aftermarket guys usually don't say much about their 99-04 collector size because they have to leave them stock (2") so that people can use them with their stock Y-pipes. When you do decide to get a set of aftermarket headers be sure to get 94-98 shorties because they will have the 2 1/4" exhaust, you will have to change your Y-Pipe to use this larger size.

In fact anyone that has a 99-04 using 94-98 Headers must either have a shop enlarge the inlet of the Y-pipe to 2 1/4" or purchases a Y-Pipe from a 94-98. It would be cheaper to have the shop do it. I was charged $5for eachexpansionon acustom exhaust setupfor my truck, CHEAP!

Now I am not sure if the exhaust diameter itself shrunk in 99-04 or if it was just the inlet that changed. I can do a little more research into that.

Ultimately its still far cheaper than aftermarket headers

You can also have the 94-98 Ceramic coated like I had mine done. Ceramic coating the inside of them is very important too to help the exhaust flow through and to aid it scavenging. This process can become a little expensive.

Now for the main benefit of the 94-98 headers is that they are 3-1 design which promotes horsepower and torque, the primaries are almost 1/4" larger, the Collector is 1/4" larger and these don't crack

NeoTokyo

Now as for porting, like I said you can purchase a flap wheel sander from Wal-Mart, Home improvment stores like Lowes or go to Grizly's website and order one.
You can also usea cartridge roll or a carbite burr.

I would stay away from carbide burrs if you are new at this, they can be very unforgiving (Personal experiance, luckily I didnt go too deep)

Start off by marking the Diameter of the porting that you would like to go to, next use either a flap sander or cartridge roll with 50 or 60 gritt paper on it and start slowly and evenly working away at the port. (Note: I put an oilsoaked peice of rag into the exhuast chamber to keep aluminum from getting in there.)

After you get to your mark finish the job up with some 120 gritt paper, if you really want it to shine then you could go even finer, the 120 will leavea smooth finsih but not polished.

Now I would not go porting too much if you dont have experiance or a bad head to play with first, you dont know how close a water passage could be. I am going to call SSM today and ask him how far out is a safe port job.


-Eric-

laserred38

cool. well my Y-pipe is outta there. i have 2.5" divorced duals from the cats back. so obviously the midpipes are still 2.25. but when i get the headers, i was going to have new 2.5" midpipes fabbed up to use my BBK high flow cats that i have. i have the o2 sensor bungs already. if i do this, what size flange would need to be on the midpipes to meet up to the collectors of the new shorties? and then should i just get some 94-98 BBK shorties and have the inside ceramic coated? i really don't want to deal with LT's in Cali, so this would be the next best thing i think. i really just don't want to put older Ford parts on. i'd rather go aftermarket and spend a little more. but it IS good info for the guys who don't want to spend the money on aftermarket.

NeoTokyo

When I was mentioning the Y-pipe I meant the whole thing, from cats down to the single exhaust flange going to the muffler.

If you use the 94-98 style use a 2 1/4" flange, if you use BBK's are are for 99-04 then use a 2" flange.

Call BBK and ask them about their collector to flange size, also ask them if they ceramic coat the inside of their headers, some companies do.


-Eric-

TheMichiganRA

Soooo .... long-tubes still good?

NeoTokyo

Oh ya, you cant beat long tubes

Its just for us smog governed guys in such states as California that this is a great idea for. Also good for the guys that dont have a lot of money,dont want to replace their cracked 99+ with the same thingor want to have to get LT x or h-pipes.

TheMichiganRA

I'm getting long-tubes down the road. You should do an article on whether or not to get rid of your cats and putting in mils.

NeoTokyo

Ok, that will be a couple months out but I will go ahead and make the article.

I will see if I can push my business license in the face of a few manufacturors and get some free items for the article!!!

Amanda was suppose to help me with that butI havnt seen her around forever!!!

NeoTokyo

Here is my stock headers off of the 96' that I reconditioned, ceramic coated and baked. They came out perfect!

Kikandross

Question
I wanted to get the Mac aluminum headers but now I am confused.
Should i get the shorty's or long tubes?
Which year should I get 94-98 or 99-04?

I got a 02 convertible v6 with the Mac catback exhaust.