The Complete Performance Exhaust System

Read This First!

Our website is designed to be easy to use, and to be as informative as possible. Before you go to the pages with specific product applications, we suggest that you take a few minutes to read this overview of exhaust system components. You'll find we've answered the most frequently asked questions and you'll be well on your way to planning your own header installation.

Stock exhaust systems are intended to work in a wide range of driving conditions and generally are not very efficient. Car manufacturers compromise performance for other considerations, such as ease of production and cost. Typically a single log-type manifold on each cylinder bank connects through a "Y" pipe into a single catalytic converter and muffler, with an overall pipe diameter of 2" or even less. OK for a grocery-getter, but not when you're looking for low-end power, mid-range acceleration, top speed potential, and yes, even better fuel economy. Anything that causes turbulence or back-pressure in your exhaust system reduces the power that intake or engine modifications can create. Stock manifolds contribute heavily to turbulence because all the exhaust dumps directly into a single tube. Tubular designs separate each cylinder's exhaust pulse, reducing the possibility that spent gases will flow back into an adjacent cylinder and contaminate the incoming fuel and air mixture. This is especially crucial when you're running a cam with more overlap.Simultaneously, tubular headers reduce back-pressure, allowing more fuel and air to enter the cylinder's intake stroke. Both these factors add up to more combustion efficiency, i.e., more power to the wheels. Sanderson headers will give you a noticeable performance gain; even when connected to an otherwise stock exhaust system. But it only makes good sense to look at all the components from front to back. Certainly, restricting the headers in a single pipe system defeats the reduced back-pressure you're trying to achieve.

A dual exhaust setup, properly sized for your engine is an important first priority. From there, choosing each component to work for you gets easier. The information below will help you decide what you need to get the most from your stock or modified engine.

One of the most critical decisions to make when you're building a performance exhaust system is pipe size. Bigger is not always better (see tube size information under "Lets Get Technical" ). It is very important that the pipe diameter be sized to the application and that it remains the same from the collector to the end of the tailpipe. Changing the diameter up or down within the system will "confuse" the exhaust by creating turbulence and excessive backpressure. These sizing guidelines are reprinted by courtesy of Flowmaster, one of the most respected exhaust technology companies in the industry.

Pipe Diameter	Horsepower	Engine Size
2"	100 Brake Horsepower per pipe	100 cu. in. to 150 cu. in. per pipe
2.25"	160 Brake Horsepower per pipe	150 cu. in. to 175 cu. in. per pipe
2.5"	200 Brake Horsepower per pipe	175 cu. in. to 230 cu. in. per pipe
3"	300 Brake Horsepower per pipe	230 cu. in. per pipe approx.