2003 V8 Full Exhaust System

[TRDCal]

Hi All,

I thought I'd post this here. I've finally had enough of my ticking exhaust manifolds, so I went to a custom exhaust shop (Stebro LTD) to see what they could do.

The guy I spoke to seemed keen on this project, he put a system on his 4.7 Tundra so it won't be their first 2uz.

Price is not going to be cheap! $1600 for custom header-manifolds + 900 for a single cat-back system or $1200 for a dual cat-back system. Keep in mind it's made from stainless steel and has a lifetime warranty. I thinking its well worth it since the dealer wants $2500 just for new manifolds and I'd have to install them.

If all goes well, I will bring my truck in mon. and they should be done by thurs. I'll post pics!

 

[aha2988]

NICE! I was plannin to take mine to a good buddy that works custom exhaust. Are you gonna put aftermarket mufflers in or keeping everything sounding stock?

 

[TRDCal]

NICE! I was plannin to take mine to a good buddy that works custom exhaust. Are you gonna put aftermarket mufflers in or keeping everything sounding stock?

I'm thinking I'm going to go for the dual system, both to exit behind passenger rear tire. Everything from the engine to the bumper is going to be new (except maybe the cats). It will be louder at higher rpms and at WOT but still be civilized when I want it to be.

My main reason for this is to remove the tick, everything else is just a pricey bonus.

 

[bt216]

good luck. I was just over at dirtydeedsindustries measuring and this is gonna be harder then you think.

the frame on the 4runner is 4" more narrow then the Tundra

 

[TRDCal]

good luck. I was just over at dirtydeedsindustries measuring and this is gonna be harder then you think.

Yah I understand all the possible issues. My theory is, if there's enough room for the factory one then there will be enough room. I'm ok if they can't do a full performance header, and I end up with more of a manifold design. Either way it will still be $1600ish (if I don't get the cat-back) installed with a lifetime warranty. The parts alone would cost me that if I bought them in the states. As you can see above, buying them here is just out of question.

 

[ARK_SWAMP_RIDER]

Please keep us updated, it's great to see options starting to become available. Would it be possible for you to get it dynod before and after to get factual info as far as performance gains?

 

[TRDCal]

Would it be possible for you to get it dynod before and after to get factual info as far as performance gains?

I would love to do this. I just depends when I go in and where I can find an AWD dyno. As is I think my dates are going to get pushed back.

I'm still deciding on single or dual. I thought I wanted duals but if I can get similar performance from a single I might go that way to save some coin.

 

[TRDCal]

Little bit of a setback but I'm still going in the same direction. I will bring my truck to the shop on sunday, were going take a couple hours and figured it all out. I'm still on the fence about single or duals but I will know all this by the end of sunday. Unfortunately tho, I'm going north to work for 3 weeks so I won't have an update till mid-end July. On the positive side that will give him tons of time to iron out the kink

I'll try and snap some before and after pics when its up on the hoist but it's not looking good for finding an awd dyno within a reasonable distance.

 

[STAYGOLD]

are they aware that a huge need for these exists if they could market and sell them? im supporting dirtydeeds too but options are good.

im sure you've told them but maybe you could push them to make a jig and be able to produce these.

 

[ARK_SWAMP_RIDER]

If a dyno is out (don't blame you there), would it be possible to at least try to get some average 0-60 times? I'm just curious about the performance aspect. Mine are cracked, but it's not an issue so I've not been in a hurry to get it fixed.

 

[TRDCal]

are they aware that a huge need for these exists if they could market and sell them? im supporting dirtydeeds too but options are good.

im sure you've told them but maybe you could push them to make a jig and be able to produce these.

I actually haven't dicussed the demand for these systems. I did tell him that the Toyota ones are known to crack are there no aftermarket options because at first he suggested I go check out TRD headers.

The only thing about the headers he is building for my truck are, they are going to be designed with the rest of the system in mind. So its not like I'd be able to bolt the factory cat-back system on to my new custom headers. Also to save on cost he might re-use my stock cats so its not really a full bolt on system that's all-inclusive which you could ship in the mail, they kind of need your truck. Either way, I'll mention it and see what he says.

If a dyno is out (don't blame you there), would it be possible to at least try to get some average 0-60 times? I'm just curious about the performance aspect. Mine are cracked, but it's not an issue so I've not been in a hurry to get it fixed.

Yes this is much more feasible. Ill find a flat road where I can use a landmark and do all the runs from the exact same spot. Also I just took of my Volant CAI temporarily so that the engine will be a stock as possible. Plus don't want the CAI noise to be in the way when I first hear the new exhaust notes.

 

[STAYGOLD]

i can deal with fabbing what i need to in order to get it to my cats, exhaust etc. i wouldn't pay $1600 a pop though. if you wouldn't mind, ask what they would make a duplicate manifold for when you're there. i would greatly appreciate it. best of luck with this. ive done plenty of exhaust work and i don't want to touch this endeavor!

 

[TRDCal]

i can deal with fabbing what i need to in order to get it to my cats, exhaust etc. i wouldn't pay $1600 a pop though.

Well i'm stuck with no other options. I will eventually need to pass an emissions test and the ticking is getting to a point where I have to do something.

 

[STAYGOLD]

sorry, that came out wrong. i just meant that if the shop could come up with manifolds/headers for me i could do the rest myself. i think that is a fair price considering that is in line if not under Toyota's and then you're getting the same bunk stuff. i meant i wouldn't pay $1600 for the mani alone.

i wasn't bagging on you by any means! hope all goes well with it.

 

[TRDCal]

sorry, that came out wrong. i just meant that if the shop could come up with manifolds/headers for me i could do the rest myself. i think that is a fair price considering that is in line if not under Toyota's and then you're getting the same bunk stuff. i meant i wouldn't pay $1600 for the mani alone.

Yeah I get you, I'm sure they could make a simple set of manifolds but so could any exhaust shop so would it really be worth it to have them shipped from Canada? I'll still ask tho.

Also, at first the price shocked me but I'm starting to understand it alittle better. Its not just $1600 for a set of headers. They're going to do everything, and there will be alot of work involved especially with taking the old manifolds off (Gone through 9 saltly winters). And I'm sure a shop in Ottawa charges no less than $80/hr and he said 4 days for the full system so lets say it'll take 2 days to do the headers. Heres how I break it down:

Labour: $1280 = $80/hr x 16hrs (This is where it hurts )
Materials: $200 = Stainless steel, new gaskets, nut & bolts etc.
Total: $1480

That leaves $120 for anything I forgot, "shop" or "tooling" fees (i've seen those before...rip off) unforeseen issues, profit....I don't know it was only an estimate.

Anytime you go into a shop, your paying mainly for the labour. This is why I normally do everything on my vehicles but I'm hardly a welder and I hate working on exhausts. My old Corolla had its fair share of leaks and now my 4runner, which is why they're one of my bigger pet peeves.

 

[TRDCal]

Just got back from the shop...they have my truck now. I won't see the final product for three and a half weeks because of work but it'll be worth it in the end.

I decided to go with the brushed stainless dual system both pipes are going to exit out behind the passenger rear tire. Headers up front with the stock cats welded on and delete the third cat. Everything is made in house, their going to put in an x-pipe in the system as well as design a muffler with an x-pipe inside.

One of my concerns was the system getting damaged if I go off road. So their going to build everything a slim a possible and really tuck it away. Also he mention he'll build a skid plate for the muffler lip.

@ARK: I was able to get some videos of 0-60 times etc before I dropped it off. I'm just playing around with movie maker, editing them and stuff and its my first time using the program so it could take a while

@STAYGOLD: In all honesty, I don't think he's interested in building a simple (similar to stock) manifold for the 4runner. He had a large Porsche coupe and a BMW M Coupe in the shop when I went so I doubt he's interested in selling bargain manifolds. If you brought your truck to him he may be willing build a simple manifold if you wanted but I think they aim more towards the side of performance. He might be able make you a set of headers, I didn't tell him to make a jig of my truck but i'm sure they would think of that, its for his own benefit and he did say he has many jigs.

 

[ARK_SWAMP_RIDER]

Thanks! No rush on the videos, mostly just using to see what type of benefits tits provides. Next problem is gonna be finding a shop near me for the work.

 

[TRDCal]

Thanks! No rush on the videos, mostly just using to see what type of benefits tits provides.

From an early editing standpoint, my 0-60mph looks to be between 8 and 8.5 secs which is slightly slower "expected". I do also have 2 more old videos of 0-60 runs, one before and after my CAI install but I never editied them and they weren't done on as flat of a road *cough* I mean track :

Anyways...when its all said and done I'll post all the videos, maybe on youtube.

 

[rebelbowtie]

so will short or mid length headers also not fit on a 4Runner or just full length headers? also curious as to how well the factory manifolds flow? i ask because coming from my area of know how (GM LSx truck engines) the factory manifolds are very high flowing and little gain other than sound comes from anything other than full length headers.

 

[TRDCal]

so will short or mid length headers also not fit on a 4Runner or just full length headers? also curious as to how well the factory manifolds flow?

I not sure how long the headers are going to be, we weren't able to put the 4runner up on the hoist but hes going with the most performance oriented design while staying within the "budget".

Its a bit of a joke how restrictive the stock system is, ill take pictures of it when its off. Each cylinder bank has a simple bar manifold, and then the factory Y-pipe cuts the exhaust diameter down by half on each inlet pipe. And to top it off that third cat and the stock muffler possible restricts some flow as well.