Interest in Custom built 4th gen V8 4.7 Doug Thorley Headers

Would you like the DT headers to have a Highflow catalytic converter?

  • Hell no! Open and loud.

    Votes: 35 9.1%
  • Yes, I would like to be legal.

    Votes: 283 73.9%
  • I don't care either way as long as I get them!

    Votes: 65 17.0%

  • Total voters
    383
Hi guys, the last time I talked with them. (After I sent them
A diagram of the manifold.) The phone call ended in "wow, that's going to be really hard to pull off, I'm going to have to talk it over with the engineers. that was a week and a half ago. I'll try to contact him this week. If they can't/don't want to do it I want to know either way. And I will relay that info here.
 
Grr

Hi guys, the last time I talked with them. (After I sent them
A diagram of the manifold.) The phone call ended in "wow, that's going to be really hard to pull off, I'm going to have to talk it over with the engineers. that was a week and a half ago. I'll try to contact him this week. If they can't/don't want to do it I want to know either way. And I will relay that info here.

That does not sound promising...

Bad news for me as mine are getting downright obnoxious and I think I will have to do something pretty soon. I hate to spend my hard earned money on another factory set but it seems there is no other option.
 
That does not sound promising...

Bad news for me as mine are getting downright obnoxious and I think I will have to do something pretty soon. I hate to spend my hard earned money on another factory set but it seems there is no other option.

I just had a thought, it might not be cheap initially but thinking long term it might pan out.

Would it not be possible to buy a set of factory manifolds and then before getting them installed take them to an exhaust shop or a fabricator of some sort and maybe they can beef up the problem areas? I guess the cracks tend to happen right where the pipe meets the flange, right? could they not beef that up before installing it that way it doesnt crack? just a thought since there are zero options available to those that need them.
 
After months of playing phone/email tag. I'm waiving the white flag. After they saw a diagram of the manifold. They just gave up and stopped responding. All I can say is that I tried.


If someone in S. Cali wants to pickup the ball, feel free. Since I'm in Maine. I cant just drive over an talk to them. (I do visit CA a few times a year but still)

Sorry guys.
 
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Add me to the want list, with or without cats makes no difference to me...

My Brother-in-laws 2005 has a leaking manifold now to.
 
Add me to the want list, with or without cats makes no difference to me...

My Brother-in-laws 2005 has a leaking manifold now to.

I beleive this thread is dead. Doug Thorley stopped replying after they reviewed and understood what they were dealing with.

IMO, we should start collecting data of those who have already replaced and of those who need to replace their manifolds and with reported mileage. We should take this info back to Toyota with numbers and fight for a better replacement part as there is zero aftermarket support for this.
 
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I sold my 2004 V8 after both sides cracked. I was quoted $3500 Canadian ($800 per manifold) to replace them.

Selling the truck was a terrible mistake. It is now a year later, and I own a 2012 VW GLI and a 1992 4Runner. I am debating selling both to buy another 06+ 4runner V8.
 
Can someone post pictures or sketches showing where the stock manifolds are cracking? I am in the rust belt with 41,000 miles in my 2008. I would like to prevent this, if possible. Would some kind of protective paint or coating work?

I will also be up for headers. However, I don't want to be part of a first batch. I would like to first hear about reliability, noise and easiness to install.
I had headers in two Toyota FJs many years ago. That was back when I lived in Venezuela. Those headers lasted a long time and never had a problem. Leakage would occur if the flanges are too thin and if the gaskets are not designed for really hot temps.
 

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