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

[Jason B]

I know I was late for the black friday sale, but just placed an order with Jason B and cant wait to get a set of these on my '04!!!

I will most likely be getting the high flow cats and everything else i need from him as well when the headers are done being built.

Good deal :thumb:

Made some progress on my jigs today. There's quite a bit of slop in the bolt holes so hopefully centering them up works fine.

Was I talking with you in the past about you doing this?


Doug Thorley 03-04 headers

Doug Thorley 05-09 headers

Also, the Gibson catback, which pairs great with these headers, this is on sale for a few more days.

Gibson 4th Gen exhaust

I can do any and all DT headers at a deal, not just these, just call or text 717-319-2100 for anymore questions.

 

[blackoutt]

Was I talking with you in the past about you doing this?

Wasn't me! I got the idea from Jagerzel and Trashcatmotorsport on this thread and old headers from Tman. I plan on passing two sets of headers and maybe even the jigs forward to other DIY'ers after I'm done.

 

[Jason B]

Ah, ok. I think I know now.

 

[gary87xj6]

High flow CATS

I know I was late for the black friday sale, but just placed an order with Jason B and cant wait to get a set of these on my '04!!!

I will most likely be getting the high flow cats and everything else i need from him as well when the headers are done being built.

Which high flow CATS did you end up getting and have you installed them yet? I'm looking at the headers and would like to do the CAT swap if not too expensive. CAT make and model info would be appreciated.
Thanks.

 

[blackoutt]

Installed my jigged headers today. 12 hr job for one backyard mechanic doing it by myself. Only issues are the steering shaft bolt clearance with 1" body lift as mentioned earlier and the header to y pipe joints leak like a sieve. What gaskets did you guys use? I used a 2.5" flange and gasket from summit racing and it doesn't seal well enough to the smaller stock y pipes.

 

[TrueBlue]

Installed my jigged headers today. 12 hr job for one backyard mechanic doing it by myself. Only issues are the steering shaft bolt clearance with 1" body lift as mentioned earlier and the header to y pipe joints leak like a sieve. What gaskets did you guys use? I used a 2.5" flange and gasket from summit racing and it doesn't seal well enough to the smaller stock y pipes.

Did you put some RTV on the flange gasket before you put it on? I've always done that with my exhaust donuts



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[blackoutt]

Did you put some RTV on the flange gasket before you put it on? I've always done that with my exhaust donuts



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These are flat perforated style, no rtv but I had another suggestion that these gaskets just suck and to coat them in the copper rtv. I also got some 2.25 gaskets ordered to try tomorrow if this doesn't doesn't work.

 

[blackoutt]

Well that sealed up those two joints but still sounds leaky from the headers. Directions say to retorque after 30 mins so I'll give it another go after heat cycling them tomorrow. Also catalyst inefficiency faults with no cats and one spacer on the rear O2s so I'll add another spacer and see if that works.

 

[blackoutt]

Sorry for so many posts in here but I can't find the post I've seen where someone talks about what bolt to get for better steering shaft clearance with body lifted guys. Anyone remember or have better searching skills than me?

Edit: Found it for anyone else looking, I replaced with same bolt but maybe the head on mine is larger, still rubbing in some situations.

http://www.toyota-4runner.org/2541281-post4.html

 

[Ryantobias25]

Just wanna say I've had the Doug Thorley headers installed now for over 2 months and they have performed great! I definitely did notice a little bit of throttle response when I picked her up. And they also give a pretty good sound with a flowmaster muffler


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[JustinCG]

Just wanna say I've had the Doug Thorley headers installed now for over 2 months and they have performed great! I definitely did notice a little bit of throttle response when I picked her up. And they also give a pretty good sound with a flowmaster muffler


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If you don't mind me asking, what did the total cost with labor?

 

[Ryantobias25]

If you don't mind me asking, what did the total cost with labor?

My total with labor and everything was $1,750. My labor costed exactly $1,000 and that's the cheapest I could find in my area


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[mmt]

A few notes on 05-09 installation

Get yourself each of these or equivalent in the appropriate size. You will thank me later.





Napa has the correct size studs with nuts. Nuts take a 17mm tool and are made of brass. Worked well for me but they are not factory so use at your own discretion. 2 studs and 2 nuts per pack. $5.99



For removal cut here on both sides (forward of the O2 port) with a jabsaw and drop the cat out. It will greatly increase clearance for removal of bottom bolts.



One last note: I cut the AIP tubes off of the DT headers and TIG welded them shut. You MUST disable the AIP. The AIP tube removal allowed me to install and torque both headers in about 30 minutes. HOWEVER this is for off road use only. I do not endorse doing this ever, or removing the cats. Especially if you need to pass emission testing. :thumb:

 

[Jason B]

Sorry for so many posts in here but I can't find the post I've seen where someone talks about what bolt to get for better steering shaft clearance with body lifted guys. Anyone remember or have better searching skills than me?

Edit: Found it for anyone else looking, I replaced with same bolt but maybe the head on mine is larger, still rubbing in some situations.

http://www.toyota-4runner.org/2541281-post4.html

That bolt will ONLY be needed for those that are LIFTED. Thanks for finding that. It's an easy trick.


Doug Thorley 03-04 headers

Doug Thorley 05-09 headers

Also, the Gibson catback, which pairs great with these headers, this is on sale for a few more days.

Gibson 4th Gen exhaust

I can do any and all DT headers at a deal, not just these, just call or text 717-319-2100 for anymore questions.

 

[Inv4drZm]

Get yourself each of these or equivalent in the appropriate size. You will thank me later.

View attachment 240009

View attachment 240010

Napa has the correct size studs with nuts. Nuts take a 17mm tool and are made of brass. Worked well for me but they are not factory so use at your own discretion. 2 studs and 2 nuts per pack. $5.99

View attachment 240014

For removal cut here on both sides (forward of the O2 port) with a jabsaw and drop the cat out. It will greatly increase clearance for removal of bottom bolts.

View attachment 240015

One last note: I cut the AIP tubes off of the DT headers and TIG welded them shut. You MUST disable the AIP. The AIP tube removal allowed me to install and torque both headers in about 30 minutes. HOWEVER this is for off road use only. I do not endorse doing this ever, or removing the cats. Especially if you need to pass emission testing. :thumb:

Nice! With my body lift maybe it will be even easier! Do you think if I am going to cut off the AIP tubes anyway, I should just buy the 03-04 headers instead? I already have the AIP bypass kit installed and am wondering if the tubes really make it that difficult to install?

 

[mmt]

Nice! With my body lift maybe it will be even easier! Do you think if I am going to cut off the AIP tubes anyway, I should just buy the 03-04 headers instead? I already have the AIP bypass kit installed and am wondering if the tubes really make it that difficult to install?

You will need to buy the 2005-2009 headers and cut them off and weld them shut. The 2003/2004 headers do not have the "ear" on them to seal the port going into the combustion chamber.

I wish DT would offer the header with a solid ear and no AIP tube "for offroad use only". Lol

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[mmt]

Here are the heads to show the difference

2003-2004



2005-2009

 

[Marfy]

Installed pics and a sound clip of the headers with 2 cats deleted, custom y and magnaflow exhaust entering a tunnel.

https://clyp.it/x0xg3ble

 

[sprygsxr]

Not something I can do myself, but here is the almost finished product on my '04

 

[V8Limited4wd]

Anyone in the DC/NoVA area get this done yet? Still have my headers sitting in a box.