11-28-2018, 11:11 PM
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#1
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Join Date: Jan 2017
Location: Oregon
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Real Name: Ruben
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Join Date: Jan 2017
Location: Oregon
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Real Name: Ruben
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Installing Doug Thorley Headers on 2005 4.7L V8 w. 2" BL
Hello to you all,
I bring you all now the story of how I installed 05-09 Doug Thorley Headers on my 05 4Runner which has 2" BL, but not after I bought the 03-04s Headers and spent 3 months driving back and forth taking my headers off a grand total of 4 times before coming up with a solution!
Let us begin:
Exhaust tick started, tried to ignore it, it got much worse and I started to hate driving my 4runner. Found this Doug Thorley Header solution and I rationalized in my head that it was worth the money and that it will be the last mod I'll do ( Yeah right -_- )
After talking with Jason from Burtman Industries I learned that the 03-04 headers were "exactly" the same as the 05-09s except for not having an EGR tube and something else, which I'll mention later on.
I ordered the Headers, (2) Magnaflow catalytic converters and the 4.7L Air Induction Pump Bypass Kit and Exhaust Port Plates off of eBay, which you need for the 03-04s because they do not have an EGR tube.
So long story short, the 03-04s did NOT fit because of the 02 sensor bung placement on the headers, they were drilled into the bottom of the header making it impossible for my female end to fit, on top of the fact that the steering shaft was entirely in the way. This is the other difference I was talking about that neither myself or Burtman saw coming, guess that's what happens when your blazing a trail into uncharted waters and Doug Thorley said they will NOT sell their headers to people with Body Lifts 
So I left my car at the shop as I tried brainstorming a solution ( the shop is 2 hrs away from my home by the way, so I had to get a ride back home ) and I came to the conclusion that the 05-09s would be the best solution since there were no solutions coming up for extending 02 sensor wires.
Obviously I couldn't return the 03-04 headers because they already had a pair of cats welded to them. Here is the post where I SOLD the 03-04 pair and there's more information there.
http://www.toyota-4runner.org/sale-t...-%7C-sold.html
So I got bought a set of 05-09 Headers and another set of Magnaflow Cats, had them welded up again and drove back to the shop and it still wouldn't clear the steering shaft ( we "dimpled" previously a little ) so this is where I lost my mind and took a hammer and blow torch to them until they fit 
[ Also I still had the $199 4.7L Air Induction Pump Bypass Kit that you connect to your Air Intake which I didn't even "need" anymore because the 05-09 Headers come with the EGR tube so it's more of a precaution at this point in case the "computer/sensor" goes out, but I'm told it costs a lot of money to replace and if you don't your Check Engine light will stay on ) but the thing is that my check engine light will probably always be on because of one reason or another so it's just an ornament in my engine bay now ] 
Also if you want to hear what the 4runner sounds like with the headers installed, check out the link below!
https://www.youtube.com/watch?v=PMwzCJZCWtM
Here come the pictures:
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Last edited by Cpt_Romania; 12-04-2018 at 03:55 PM.
Reason: Mistake in Title.
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11-28-2018, 11:52 PM
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#2
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Join Date: Aug 2018
Location: Phoenix, AZ
Age: 23
Posts: 98
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Member
Join Date: Aug 2018
Location: Phoenix, AZ
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You gotta get around to doing a build thread man, I'd love to see more of your rig!
Sent from my Pixel 3 XL using Tapatalk
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11-29-2018, 12:31 AM
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#3
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Join Date: Nov 2014
Location: Thornbury
Posts: 252
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I have a 1.25 body lift and also have rubbing issues. I was able to grind a bit off one of the steering shaft bolts and it isn’t too bad. For what ever reason, when I reverse and turn, it rubs a little more.
Anyway, I appreciate how hard you worked to get these to fit but I have to say, seeing what you did to get them to fit makes me really sad.
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[Sold] 2007 Limited - V8 4WD
Stock Rear RAS / Bilstein 5100s / OME 885 / RB 1.25 BL / BFG KO2s - 275/70R17 / SCS Ray 10 - Brushed Gold /
XenonDepot Hid Kit (lows) / Aftermarket Yellow Fogs w/ XenonDepot HIDs / DT Premium Long Tubes / Custom Y w/ 2 cats deleted / full custom exhaust pipe with magnaflow / aFe CAI / MAF Calbrator
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11-29-2018, 08:38 AM
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#4
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You beat that header like it owed you money!
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2006 V8 4Runner Limited
FOX 2.5 DSC | Total Chaos | Dobinson 677V | Doug Thorley Headers & Y-pipe | Gibson | RCI Metalworks | BudBuilt | SCS Ray 10 | Wildpeaks 285/75/17 - 34s
Instagram @ TXT4R
Last edited by Todapwr; 12-01-2018 at 12:10 AM.
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11-29-2018, 01:17 PM
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#5
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Join Date: Aug 2018
Location: Denver
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Real Name: Calvin
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Gah that sounds so good
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11-29-2018, 02:52 PM
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#6
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Join Date: Jan 2017
Location: Oregon
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Real Name: Ruben
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Member
Join Date: Jan 2017
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Quote:
Originally Posted by K-D-Runner
You gotta get around to doing a build thread man, I'd love to see more of your rig!
Sent from my Pixel 3 XL using Tapatalk
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Soon 😉
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11-29-2018, 02:53 PM
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#7
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Join Date: Jan 2017
Location: Oregon
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Real Name: Ruben
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Quote:
Originally Posted by Marfy
I have a 1.25 body lift and also have rubbing issues. I was able to grind a bit off one of the steering shaft bolts and it isn’t too bad. For what ever reason, when I reverse and turn, it rubs a little more.
Anyway, I appreciate how hard you worked to get these to fit but I have to say, seeing what you did to get them to fit makes me really sad.
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Don't be sad, it was worth it, who needs shiny chrome headers anyway 😁
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11-29-2018, 03:33 PM
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#8
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Join Date: Jun 2016
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Quote:
Originally Posted by Cpt_Romania
Don't be sad, it was worth it, who needs shiny chrome headers anyway  |
More like who needs exhaust flow??? I’d throw a wide band on there to be sure your a/f ratio isn’t all jacked up
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1995 ECR33 GTS-T (sold)
1990 s13 coupe TONS of work
2005 4Runner Sport V8
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11-29-2018, 04:14 PM
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#9
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Senior Member
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Join Date: Sep 2006
Location: Hoover, AL
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Real Name: Billy
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Looks like you took 2 x fukitalls and went to work...
I will apologize for my ignorance, but why would DT make headers
that do not fit around the steering shaft...? Or is that because of your Body Lift?
I still have my DTs in the box... trying to figure out when to install them...
Plus I need someone to help me weld them together. PITA....
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2005 4WD V8 SportEdition MY BUILD
ICON 2.5 resi-Stage 3, K&N CAI, Gibson Exhaust, Ash Tray Kit, Husky Cargo Liner, Husky Floor mats, Rear Diff Breather Extension, Driver side grab handles, 285/70R17 BF T/A K02, RIGID Hyper Spots in Scoop, Grill, Pillar, Rack front and back, Wilson 5000 magnetic, Stryker 490 CB Radio, Gamber Johnson Floor Mount, WILCO rear tire Carrier, Gobi Rack, StopTech Drilled and Slotted Cryo Brake Rotors, RPM Front Bumper, DT Headers (Not installed)
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11-29-2018, 04:43 PM
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#10
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Is this serious?
There is no way you are getting improved performance out of those. Jesus Christ man! Seriously, is this serious?
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Last edited by Crusifix; 11-29-2018 at 05:04 PM.
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11-29-2018, 05:11 PM
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#11
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Senior Member
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Join Date: Sep 2015
Location: Kansas
Age: 28
Posts: 4,304
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Senior Member
Join Date: Sep 2015
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Quote:
Originally Posted by Crusifix
Is this serious?
There is no way you are getting improved performance out of those. Jesus Christ man! Seriously, is this serious?
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As long as it doesn't break again like the stock manifolds do I'd say its a win. With the improved y pipe it could easily have the same performance as stock, the stock y pipe section is pretty restrictive
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2005 4R Sport 4WD "The last of the V8s!" - Custom TIG'd SS Dual Exhaust - King 2.5" +2 LT. - ARB Front & Rear - 37's - Dana 60 - Build Thread
2005 Tundra 2WD Regular Cab V8 - Chopped Frame - Short Bed Swap
1977 Celica Liftback - LFX Swap - Build Thread
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11-29-2018, 05:16 PM
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#12
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No. First of all, now you have very uneven flow from not only one bank to the other, but you also have uneven flow from each individual primary pipe. He is completely negating what a header, or even the most basic manifold is supposed to do. I come from an automotive performance background, and from what I can tell in the photos, there is at least one header pipe with about 80% restriction, and one that isn't too much better. You have those two cylinders fighting against the free flowing cylinders now, and this will cause heavily reduced performance and efficiency. But, don't take my word for it. This thread has gone viral on other automotive sites for being a huge "WTF"?
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Last edited by Crusifix; 11-29-2018 at 05:34 PM.
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11-29-2018, 05:28 PM
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#13
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Senior Member
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Senior Member
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Quote:
Originally Posted by Crusifix
No. First of all, now you have very uneven flow from not only one bank to the other, but you also have uneven flow from each individual header pipe. He is completely negating what a header, or even the most basic manifold is supposed to do. I come from an automotive performance background, and from what I can tell in the photos, there is at least one header pipe with about 80% restriction, and one that isn't too much better. You have those two cylinders fighting against the free flowing cylinders now, and this will cause heavily reduced performance and efficiency. But, don't take my word for it. This thread has gone viral on other automotive sites for being a huge "WTF"?
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Don't take your word for it, take other random people's opinions on the internet too. LOL.
Its a durability mod. Its still better than the stock ones that crack.
Compared to these headers, the stock manifolds probably have a 25% restriction on each cylinder due to their diameter decrease, sharp bends, and short runners.
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2005 4R Sport 4WD "The last of the V8s!" - Custom TIG'd SS Dual Exhaust - King 2.5" +2 LT. - ARB Front & Rear - 37's - Dana 60 - Build Thread
2005 Tundra 2WD Regular Cab V8 - Chopped Frame - Short Bed Swap
1977 Celica Liftback - LFX Swap - Build Thread
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11-29-2018, 05:29 PM
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#14
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Quote:
Originally Posted by Inv4drZm
Don't take your word for it, take other random people's opinions on the internet too. LOL.
Its a durability mod. Its still better than the stock ones that crack.
Compared to these headers, the stock manifolds probably have a 25% restriction on each cylinder due to their diameter decrease, sharp bends, and short runners.
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Looks very durable. No weak spots created at all in the tubing structure..
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11-29-2018, 05:32 PM
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#15
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Wow, what a train wreck. Does Doug Thorley make headers that are actually compatible with the 4Runner?
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