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#1068550 - 11/13/20 01:17 AM Headers, full exhaust, and a few install pics  
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I wanted to do a full exhaust on my 305 sbc. I wanted to go the longtube route. I tried the dougs 308 first and they did not fit at all. I decided to order a set of raw patriot 8096 that way I could modify if needed. I went with a g-force 2004r crossmember and the hooker 2.5" stainless exhaust which comes with the stainless v304 straight thru muffler design. This kit was made for ls engine but i liked the kit and that it exited out the side behind the rear wheels so I wanted to make it work. BADSS helped me with quite a bit of advice and direction of where I wanted to go with this. I also used the mr gasket ultra seal gasket per his recommendation. The parts i used are:
Headers $236
https://www.summitracing.com/parts/pte-h8096
Hooker 304 stainless exhaust kit $753
https://www.summitracing.com/parts/hok-70501363rhkr
G force crossmember $235
https://www.crossmembers.com/produc...utlass-grand-prix-regal-crossmember-400/
I also used mr. Gasket ultra seal collector gasket, 3 wire o2 sensor, 1 wire to 3 wire harness for o2 sensor, 2 weld in o2 sensor bungs, arp 12 point header bolts and high collar lock washers (i can't remember who made them, BADSS recommended them). I went with Taylor cut to fit plug wires and Made For You Products wire routing (I copied SSLANCE).

I wanted to try to do a detailed write up because I know people are always looking for different exhaust options. If any questions just ask.

#1068551 - 11/13/20 01:33 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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My first goal was to make sure my new headers cleared angle plug heads. Im building the 305 this winter and these are the trick flow heads that i will be using. I tested them with the orginal ac delco 3/8" reach plugs. The heads call for a autolite 3/4" reach so they are a bit shorter. The headers easily cleared all plugs and wires on the angeled plug heads.[Linked Image]

The next goal was to see if they fit and what areas needed to be modified. When I first put them in I was glad to see I had easy access to oil filter and starter if needed.
[Linked Image]

To install the car was on cribbing. I removed old exhaust, starter, plugs, oil pressure sender, and oil filter. I had to trim corner on drivers side motor mount and modify the ac bracket. The headers slid in pretty easy from the bottom if angeled right.

#1068552 - 11/13/20 01:40 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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BadSS Online content
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Thanks for the shout out. Looks great and it's always good when folks can add back to the community!

#1068553 - 11/13/20 01:46 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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The headers fit but were awfully close in some areas. I heated them with a torch and massaged them to make more room. Unfortunately i didn't take any pictures of that. One area I had to clearance a good bit on by heating was the collector where the shift indicator rod goes to the trans. In this picture you can see that area. It also shows where i tig welded in the o2 bung and had fitted it to the hooker kit. As you can see the header collector flanges were crooked from the factory. I removed the flange from the reducer, bolted it to the collector flange, cut the reducer at the needed angle and tig welded the reducer back to the flange.
[Linked Image]

Here is the final fit up before removing headers to send to coating.
[Linked Image]

The hooker exhaust kit is really well made. The issue is that its made for their ls headers but the only thing I did was cut about 2 inches out of the passenger side tube and tig welded it back as seen in this picture.
[Linked Image]

Last edited by 88ssBrent; 11/13/20 02:17 AM.
#1068554 - 11/13/20 02:19 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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thumbs!!


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If things improve with age, I must be approaching magnificent. thumbs
#1068555 - 11/13/20 02:29 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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I got the headers back from coating (thats another $200). I wanted a nice black, they coated them twice inside and out.
[Linked Image]

A couple of things i forgot to mention is that I had to put a 90° fitting on my oil pressure sensor. I put dei shielding on my wires coming off starter, they probably would have been fine but it was extra piece of mind. Here is the headers installed with the new plug wire mounting and new plugs.
[Linked Image]

#1068556 - 11/13/20 02:30 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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OK I will be "That guy".....

Are you going to stroke the 305 with a 400 crank to make a 335? If not, why spend the $$ on building the 305 when you can spend just a little more & build a 350 that will make so much more power?

#1068558 - 11/13/20 02:33 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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SSLance Online content
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Nice work. Do you have any pics of the tailpipes going over the axle?

I'm putting a plan in place to do my exhaust next...and I'm concerned about packaging with as low as my car sits.


Lance
1985 Monte Carlo SS Street Car
#1068559 - 11/13/20 02:49 AM Re: Headers, full exhaust, and a few install pics [Re: Tunedss86]  
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Originally Posted by Tunedss86
OK I will be "That guy".....

Are you going to stroke the 305 with a 400 crank to make a 335? If not, why spend the $$ on building the 305 when you can spend just a little more & build a 350 that will make so much more power?


My bottom end only has 18,000 miles on it. I wanted a little extra so this is the route I decided. With heads, cam, and the other goodies I should be around 320 h.p. at the crank with around $2200. I couldn't get a 350 or build one for that amount. Everyone says you can but i sure couldnt make it work for $2200. Also, why blow your money on a 350 you could build a ls or 383 with a little more money and have so much more power. It really is a never ending statement and you can always go bigger with just a little more money, correct? By the engine analyzer software with my combination I will making around the same power as a stock ls 5.3 as per west tech dyno.

At the end of the day I have bigger engine plans. This is just something to hold me over while I get there.


Last edited by 88ssBrent; 11/13/20 03:03 AM.
#1068560 - 11/13/20 02:56 AM Re: Headers, full exhaust, and a few install pics [Re: SSLance]  
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Originally Posted by SSLance
Nice work. Do you have any pics of the tailpipes going over the axle?

I'm putting a plan in place to do my exhaust next...and I'm concerned about packaging with as low as my car sits.


Yes, I have more pictures. If I dont have a good pictures of what you are wanting to see i can take plenty more and send them by email. I will have the car back in the air after this weekend.

#1068562 - 11/13/20 03:16 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Here is a few more pictures after I was finished. I tig welded the collecter to the exhaust pipe and also had it coated.
[Linked Image]

This picture shows where the exhaust exits. It comes out behind wheel on both sides.
[Linked Image]

Here is a picture of the exhaust system from the back looking forward.
[Linked Image]

Picture of x pipe
[Linked Image]

Last edited by 88ssBrent; 11/13/20 03:20 AM.
#1068564 - 11/13/20 03:33 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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AkronAero Online content
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Very, very nice work! Lots of attention to details; well thought through and executed.
Could be a second job for you if word gets out...
Thanks for sharing.
Gordon

#1068565 - 11/13/20 03:43 AM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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My final thoughts are no matter which longtubes you go with you are better off getting them in raw steel and getting them coated later. If you have to modify its not a big deal. Also the coating from the factory was not the best in other headers I saw. Its beneficial to order from summit as they sent another set out before i even sent the dougs back and didn't charge me any extra shipping. Im happy with the patriot 8096 headers but I went into it knowing that they would need to probably be modified to fit the way i wanted.

The g force crossmember is grade A. Only thing I did with it was drill and tap a hole for the speedometer cable bracket.

The hooker exhaust is top notch. Its hard to find a whole stainless 304 kit with stainless thru design mufflers and it fit great. For what it is and how well all the brackets are made I feel $750 is a good deal. I went 2.5" but they also make it in 3". I really like the sound .





Last edited by 88ssBrent; 11/13/20 03:43 AM.
#1068566 - 11/13/20 01:39 PM Re: Headers, full exhaust, and a few install pics [Re: SSLance]  
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Originally Posted by SSLance
Nice work. Do you have any pics of the tailpipes going over the axle?

I'm putting a plan in place to do my exhaust next...and I'm concerned about packaging with as low as my car sits.


I thought I had more pictures of over the axle but this is all I have. I will get some more detailed pictures and get them to you. Its been about three weeks since done but best I can remember there was plenty of room around the axle. It was about 3/4" away from the driverside upper arm. That was the only close place. I did have to bend the the exhaust support bracket just a little on drivers side to give me room away from upper coilover mount but no big deal.

[Linked Image]
[Linked Image]

#1068567 - 11/13/20 01:48 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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SSLance Online content
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Thanks for the pics. Given that I want 3" exhaust and also have a 9" with 3" axle tubes, my setup will be tighter I'm sure. The trick will be getting the hoop that goes over the axle exactly centered front to rear to allow for clearance on both sides under compression.

Let's hear a sound clip... I've been leaning toward Magnaflow mufflers as I like their tone and I need it somewhat quiet to make sound at some events. How loud are yours at WOT? Any done at highway speeds?


Lance
1985 Monte Carlo SS Street Car
#1068568 - 11/13/20 01:59 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Not mine but this is another install I ran across while doing research. Its also a sbc. In this picture the guy used the 3" kit.

[Linked Image]

Last edited by 88ssBrent; 11/13/20 02:00 PM.
#1068569 - 11/13/20 02:02 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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SSLance Online content
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Wow, that is close to the driveshaft! I also have a 3.5" driveshaft which makes things even tighter.


Lance
1985 Monte Carlo SS Street Car
#1068572 - 11/13/20 02:30 PM Re: Headers, full exhaust, and a few install pics [Re: AkronAero]  
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Originally Posted by BadSS
Thanks for the shout out. Looks great and it's always good when folks can add back to the community!


This forum and other forums have a lot of value to me. I feel people are more willing to help on forums than facebook and social media so I want them to stay around for future use. A lot of research I do i come across links that don't work anymore so hopefully this helps someone in the future like its helped me.

Hopefully motor will be out in the next couple of weeks and im sure i will have plenty of of questions to ask you as I rebuild. Lol. Its hard to put the car away while the the temps are still in the 70's.

Originally Posted by 86ttop
thumbs!!


Thank you 86ttop


Originally Posted by AkronAero
Very, very nice work! Lots of attention to details; well thought through and executed.
Could be a second job for you if word gets out...
Thanks for sharing.
Gordon


Thank you,Gordon! In my previous position I was a industrial mechanic (hydraulics, welding, fabrication and all that kinds of stuff). I could not stand working on stuff like this when I got home because I did it all day. Now im a industrial electrician and 90% of my work is computer based so im back to enjoying it. My dad told me "a good way to ruin a hobby is do it for a living". So i hope the word doesn't get out . Its not perfect but im satisfied with it . Once again thank you for your kind words.

#1068575 - 11/13/20 03:15 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Looks awesome all around! Thanks for sharing the pictures!


87 Black/Tan Aerocoupe
#1068576 - 11/13/20 03:16 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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How well did all of those band clamps seal everything up? Any evidence of any leaks around them yet?

I want to use V-band clamps at the header collectors and behind the mufflers and weld the rest of the joints solid. This way I can drop the whole mid section easily while the rest remains mounted in place securely. Plus, I already have V-Band clamps on my headers. Do you see anything where that would be a problem doing this with that system? I'm curious why your mufflers as slanted slightly vs sitting flat also?


Lance
1985 Monte Carlo SS Street Car
#1068578 - 11/13/20 04:27 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Originally Posted by SSLance
How well did all of those band clamps seal everything up? Any evidence of any leaks around them yet?

I want to use V-band clamps at the header collectors and behind the mufflers and weld the rest of the joints solid. This way I can drop the whole mid section easily while the rest remains mounted in place securely. Plus, I already have V-Band clamps on my headers. Do you see anything where that would be a problem doing this with that system? I'm curious why your mufflers as slanted slightly vs sitting flat also?


So far no issues with band clamps except at reducers. Not sure how they will hold up over time. The 2.5" on the reducer was a little undersized that is why I welded it. I think the v bands would work fine with this system and i was already planning to weld everything solid once i get every thing set and know its for sure where i want it. That leads to your next question, I wanted the exit pipes up tight to the body ( about 1/2") i think hooker intended them to be off the body about a 1.5" or 2" so as I was twisting them up with how the mounting brackets were it moved the mufflers in a slant. The weather was nice and we had the last big cruise in of the year so I just called it good knowing I would make some adjustments this winter. I am going to re drill the holes on the brackets and mount them back and that will flatten out the mufflers. Its just while getting the tips where I wanted and maintaining all my clearances thats how it fell. If you look in the picture that is not mine it looks like they made some modifications to mounting brackets also.

Last edited by 88ssBrent; 11/13/20 04:32 PM.
#1068579 - 11/13/20 04:30 PM Re: Headers, full exhaust, and a few install pics [Re: wxdude64]  
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Originally Posted by wxdude64
Looks awesome all around! Thanks for sharing the pictures!


Thanks for the compliment. You are welcome on the pictures.

#1068582 - 11/13/20 05:04 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Lance, you will also have way more room for adjustment if welding the kit. The 2.5" (3" in your case) od piece slides into the 2.5" id piece a whole 2.5". Hooker states that it has to slide in the full 2.5" til it stops solid to seal when using with the tube clamps. If you need to shorten something a little you can trim the od piece if you need more length to fine tune adjusment you have the 2.5" of play. Thats my plan to fine tune it this winter because it doesn't have to be seated all the way if welded. I hope that makes sense?

#1068583 - 11/13/20 06:01 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Like any car project it will Nickle and dime you to death so i feel its important to do research and know what all you need and a realistic cost before you get into it so here is my cost with me doing the labor.

Header coating $200
Headers $236
Exhaust kit $753
Crossmember $235
Mr. Gasket ultra seal collector gaskets $15
3 wire o2 sensor NTK21003 $19
1 wire to 3 wire o2 harness from eBay $19
2 -o2 bungs off ebay $20
Add a circuit for power to your heated o2 sensor $5
Arp 12 point header bolts $21
Trans dapt 4710 high collar lock washers $4
90°npt fitting for oil pressure sender $5
Dei wire jacket for starter wire DEI 010475 $27
Taylor Street thunder cut to fit 8mm plug wires 51006 $36
Msd plug wire crimp tool 3503 $11
Made for you loom brackets 5082494 $30
Made for you looms 5075611 $37

Total = $1673

After typing this it reminded me about the heated o2 wiring. With advice from Bob (mmc427ss) and Buick Runner I pulled my power off the choke heater circuit and it worked great. I also welded a o2 bung in each header. One for the ccc o2 and the other for the speedhut a/f ratio gauge o2 that im currently waiting on.




Last edited by 88ssBrent; 11/13/20 06:08 PM.
#1068585 - 11/13/20 08:32 PM Re: Headers, full exhaust, and a few install pics [Re: 88ssBrent]  
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Fair enough.

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