As Dale (Mt_Goat)has been somewhat of a motivator for me (Black 93's). I thought I'd share some of my trials and tribulations. I'm using a 98 4runner engine in my 93, with an R151F (it was an auto- what a pain!) and some performance mods (URD stuff). Being that the only rocks in Florida are used for landscaping, I'm not doing much to the suspension other than a bunch of OME stuff and some 31s for now. I, too am using an ORS kit along with a bunch of stuff I've made myself.

Here's what I've done to get the Downey headers 'easier' to install-
They started out pointing at the frame:


It took a few added pieces to each side to get the collectors in the right spot for the Y-pipe: (I'm using 2.5" buick-ball flanges)



A little grinding in the ports to take out the machine welds:


Now, after a few welded on bends and some grinding... I'm having them Ceramic coated this week.


More when I get the Y-pipe and exhaust done. Thanks to Dale for posting so many pics- I'm somewhat of a 'visual guy', and they've really helped. I hope I can do the same with some of my solutions...

 

nice job. good choice on the ball-type flanges... friend of mine did the exact same thing.

 

OK- coating complete. Time to mock them up & finish the Y-pipe. Got the Walbro fuel pump installed yesterday. I had to slightly bend the outlet pipe (up) due to the Walbro being about 1/16" taller.

 

Nice! Are you going to wrap you fuel line that is right next to the pipe? Or does the coating hold in that much heat? I've been thinking of headers because I'm charged and my x-over is cracking due to no flex pipe

 

Those came out nice! Hope you didn't grind away too much of the weld on those. Are you planning to use flex joints near the collectors?

 

Dale-
That's a consideration- I had planned on using the buick balls to cover a bit of the movement. The whole system hangs on rubber hangars, so I'm not to worried about movement. For now, I picture the two ball flanges, crossing down and over, meeting into the Flowmaster Y-colletor (where the O2 sensor is), then a flex joint to the rest of the system (or another 3" ball joint).

It may look like I went thin, but I went to great pains to make sure they were thicker in the weld areas- If you saw them up close, you'd see that they taper up and down a little bit.

Now to get it all together and get the FTC running...

 

Well- The Walbro required a bit of work... with the fuel sock I had mounted, It was about 1/4" too long, so I cut 1/4" out of the pump mounting bracket & rewelded it. The fuel pipe neded a slight 'recalibration' too; a slight bend fixed that. I also finished the Y-pipe; more pics tommorrow.

 

looks good nice fab work

 

Wow, I guess our stock fuel pump mounts are different (wish I'd taken some pics of that now) My Walbro 190 fit right in place, I think I just bent the mount slightly. Does that rubber help with the noise?

 

Don't know yet- but I guess that's a good thing, huh? You have to be next to the tank to hear it running. I found this out when testing the pump & new lines. As for fit- did you use the same drop-sock filter? The stock pump came straight out & didn't drop down like the sock I used. I'm sure if I looked around more, I'd have found the right sock.

Man I can't wait to drive this thing!

 

I can't remember now, I did that install before I took out my 3.0. I've slept many nights since then.

 

Does anyone know if that modification to the headers affect california smog certification? Also, I have to use 2 cats and I'm not sure I can arrange them properly if they come off headers first.

 

Yeah that would be hard to fit two cats after the cross-over, but it must be possible. Might try searching the 95.5-2004 section to see how they do it.

 

Good idea. I'll check that out. Are you running manifolds with the x over? I wanted the headers thinking that they would be best for the SC. How does it run with the SC and upgrades you have?
The easiest way is to run the x over so its looking like that's the way I'll go.

 

Yeah stock 2001 manifolds seem to work great to me.

 

Is there a difference in manifolds? My donor engine is a 98. If there is a difference, I could probably pick up a newer set for pretty cheap and have some gain over stock.

 

Yeah those are different but not sure how much difference there is flow wise. Does your donor have EGR? If so, the newer design won't have the port for it.