M&K Tuned Headers for 2.4L - 3.0L Engines
 

This project has been on the shelf for far too long. We finally just bit the bullet and made it happen. After years of dealing with aftermarket headers of every type and building race systems for shops I pretty much know what works and what fits well when it comes to street/track headers. The design constraints for these are:
> Stainless Steel as with all our other products.
> True equal length 31" primaries and 9.5" Secondaries, tolerance +/- 0.25"
> Smooth swooping bends.
> F1 collectors.
> OEM early exchanger exit locations and flanges to fit OEM inlet mufflers.
> Collector location that allows room to use megaphones by simply adding flanges.
> Room to add heat exchangers that minimize installation difficulty.
> Low profile for added ground clearance for lowered cars.
> Proper sizing per application.
We're starting out with 1.5"OD primaries for the 2.4-3.0L engines then move to 1.63" for Carrera/964 and 1.75" for large displacement and race engines.
Yes heat exchangers will be an option. The long straight path from the main bends to the collector then exit flange was done purposely to simplify the design of heat exchangers. Yes these look similar to some of the other brands of headers out there but there is only so much room to work with and so many ways to skin a cat. The devil is in the details and we've put in all the details to make these a true performance piece with durability that will last as long as you own the car.
Testing should be completed soon so we can offer these to our host and fellow enthusiasts.

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Brian, they look great and I wouldn't expect anything less from you. You really make some quality stuff.

Love it! Price point and approx gain over something like George's Euro headers known? That nice collector will be worth some bhp up top.

Thank you!
Yes F1 collectors and equal length tubes. I've measured Georges and they're not even close to equal length. I've thought about comparative testing but would prefer a 3rd party do that for validation. We've been involved in so many header builds and dyno runs with race shops that I know what to expect out of these. You're not talking huge gains but every bit helps. Price point will be a bit higher than our RSR headers simply due to material cost for the longer tubes. Hope to be working on heat exchangers next week ...

Any updates?
currently building a 3.0 mfi high butterfly motor for road and circuit. 8k rpm but streetable. looking for exhaust with HE to optimize both driving around and to circuit and on circuit.

Yes I'm actually test fitting the heat exchangers this weekend. The shells are in place and all that's left is to position the heater pipe inlets and outlets. Really hate to cover up our F1 merge collectors but that was part of the design plan to keep the heat exchangers simple. The merge collectors have double slip joints that are fully welded to prevent exhaust leaks for the life of the product. It's overkill but that is what we do. This is the last step in a very long process. We expect to wrap up testing an a few short weeks then begin production. I'll need to take a look at the specs on your 3.0L MFI engine to determine build parameters for the headers.

This picture is of the heat exchangers in process. The end product will of course not have the tab strip and will be fully welded.


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Brian, well done. I can only say that Brian's stuff is really to pretty to put underneath the car. I have recently installed his headers (no heat) and polished street muffler on my 88. I am thrilled with what I purchased.......

This really looks like the ticket, checking all the boxes with top quality. Can you say yet if the heat exchanger version will allow reasonably easy valve cover removal and valve adjustment access, without loosening any part of the header or exhaust system? If so, I think that would make it perfect.

very nice!

Nice work. Great looking headers.

Would you mind sharing the alloy and thickness of the tubing? Thanks.

Thank you!
A major consideration for all of our products is ease of installation. I've been wrenching on these cars for decades and have used those experiences to make it easier on the guy at ground zero skinning his knuckles. These headers are block huggers with as much ground clearance designed in as possible. The sacrifice is the exchangers are really close to the valve covers. The up side is you can remove these headers in a matter of 15 minutes with three hand tools. I just did it today 4 times on and off per side and it is a snap. Taking a break now, I'll post up some pictures later on today when I'm finished mocking up where the inlets/outlets will go.

These look amazing.

Any ideas on approximate MSRP?

Thank you!
Here is a picture of the double wall welded slip joints at the collector. We decided on this as added protection against any possibility of exhaust fumes leaking into the exchanger.
Oil dripping on the heat exchangers is another issue that was addressed. The boxes we make for our RSR / Carrera headers has a service panel built into the bottom so you can clean them out. These will be sealed so a round shape was chosen that will allow the oil to migrate and drip off with no place for it to enter the exchanger.
Pricing target is the same as our RSR/Carrera headers and exchangers. These might end up a little more due to the extras that have been designed in.

http://forums.pelicanparts.com/uploa...1572455274.jpg

sanitary!

They look great, you should offer the option to use other spacing for the mufflers inputs

Interested in these with heat exchangers and your new active exhaust with the gt3 style.

Have a few questions, if you don’t mind:

1) could an O2 bung be added on one or both banks? I’d like to have the stock narrowband O2 on the left bank and wideband on the right for AFR gauge

2) any ballpark idea what the dB would be for idle, cruise and “getting on it”. Not looking for anything exact... just trying to get a sense for what could be expected

Double welded slip? Looks good.. Similar to the ones you and I had spoke about last summer

Thank you Bill, yes there will be several options to accommodate secondary systems. One version I'm working on will be used to connect to 996/997/991 GT3 mufflers, another will have v-bands to connect to megaphones or whatever you wish.

Yes there will be an O2 bung just like on our Carrera headers.
Active exhaust is based off our Street mufflers. Sound level at idle and cruise is a touch louder than stock, ~76dB at idle and cruise, anywhere from 86-100dB at redline depending on adjustable baffling options. It sounds absolutely wicked when you stomp it!

Yes double welded slips. The exchangers for these headers will be sealed so it is critical that there be no chance of cracking or leaks. Can't do stamped exchangers like OEM so beefing these up to be the best they can be. I've had this design on the back burner for years, glad to finally be getting it done.

Been running the MKM34AE Active Exhaust muffler setup on the SC for a few weeks now and man I love it. The 1.5" primaries on these headers are a good size for the stock 3.0L engine. I haven't had it on a dyno yet but the power increase is noticeable compared to OEM early header/exchangers and a stock early dual inlet muffler. You can see a peak of the OEM exchangers sitting under the car during the swap out.

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what is the gnd. clearance on that vacuum pot?

nice clamps BTW!

Active Exhaust muffler on now is a prototype, production units will have the valves rotated 45° towards the front of the car.

Brian, I sent you an email to inquire about pricing and availability with my proposed configuration.

This work is simply art.

Tremendous product

Looks like a must have for XMAS. Thanks alot Brian. I have your GT3 muffler and rear Valance. I guess I'm going to put your headers on my XMAS list. http://forums.pelicanparts.com/uploa...1572902140.jpg

Nice setup. How do you get through smog in LA?

1971 911T. No smog required

Shape/layout of these looks very similar to the Bursch headers? I recognize the stainless construction, welds, F1 collectors of yours are a major improvement. Just wondering if the Bursch layout is mimicked here


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My understanding is that exhaust gas flows better when kept hot.
The final pipe section is close to rear of engine and is operating @ 900 degrees
So, why is the final collector pipe section not wrapped with thermal cloth????

Brian how much if any of a gain in HP over SSIs?

Or over your previous model?

When designing these headers I purchased 3 different popular models and mounted each to see which basic tubing route I linked best, and yes Bursh was one of them. I liked the layout of the tubes but that was about it. All the "cheap" headers had either the crappy flat collectors or stamped triangle merge that dumped all 3 tubes into a hole. None of them were equal length even though some are advertised as such. I smoothed the bends on the primaries and changed the path slightly to clear everything while butting up as close as possible to the engine for ground clearance. The length of the primaries was changed to 30.5" +/- 0.25" which is ideal for 3rd pulse harmonics of the medium displacement air cooled engines. Of course our F1 style collectors are used as well. The end product looks Bursh-esque at first glance but they are much different in the details.
Thermal cloth destroys the metal and looks ugly for the tiny increase you might see on a street car. Better to thermal coat the stainless if desired.
I haven't had the car to the dyno to compare against early exchangers or SSI yet. All the improvements made are tried and true, and the butt dyno can attest. We sell to many race shops who do a lot of dyno work, I am sure I will get that data as well.
Our medium length RSR headers were designed specifically for the 3.2L Carrera, these 1.5"OD long tube headers are designed for the 2.4L-3.0L engines. The Carrera headers utilize 5th order pulse timing for the Motronic engine at 5800rpm peak HP and have port matching 38mmID primaries (1.63"OD tubing). They will still be offered for that application.

Thanks for the clarifications. I agree the stamped triangle collector on the Bursch headers is a bit crude. But it seems to be a little bit cleaner in funneling than the well known SSI/George's/GT Racing chopped pipe flat collector that was copied from the original Porsche exhaust dating back to the 60s?

I didn't know your other headers were built specifically for the 3.2 Carrera engine's specifics. That's good to know!

Since we've got your ear, ever heard what prompted these BBE headers to arrive to market? Just seems odd that for years their product was basically all long tube headers and their proprietary rectangular muffler that always split. Then in the recent past these "early" headers came along. Seems like Patrick likes to use them. Maybe they finally decided to make something that fit the typical banana mufflers?

http://forums.pelicanparts.com/uploa...1573589685.jpg

Can't say what prompted the design change of the above headers but we've always used the OEM dual inlet muffler position as it gives you muffler options. The goal is to get what you want, not force on you what we have.
The outboard primary design as seen above is one I rejected as the passenger's side gets too close to the main oil tank line.