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#269419 - 22/04/15 11:20 PM Wrapped headers, removed cats and exhaust baffles
Mol Offline
Just Getting Started

Registered: 28/02/13
Posts: 52
Loc: Okemos, Michigan
I wanted to wrap my headers because it was part of the look I am going for with my M3W. To do the job correctly you have to remove the pipes. The thought of doing this was scary for me at first, but I wanted wrapped headers and my friend who was going to wrap them for me said I had to remove the pipes for him to do it. Since I was going to have the pipes off, I decided I might as well remove the cats and baffles as well.

First you remove the O2 sensor.




Loosen the clamp between the pipe and header.




Unbolt the pipe mounts.




Pull the pipes apart by wiggling and twisting. The residue on this joint is Anti-seize. This product keeps metal pieces from corroding together, so that you can get them apart again if you ever need to. Before you reassemble, you will need to completely clean this off with ultra-fine steel wool and reapply a fine fresh coat. A little goes a long way.




Tail pipe removed.



It is really not that difficult to take this off.




... continued in next post...


Edited by Mol (23/04/15 12:31 AM)

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#269422 - 22/04/15 11:39 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Mol Offline
Just Getting Started

Registered: 28/02/13
Posts: 52
Loc: Okemos, Michigan
Removing the headers is not as easy because of inaccessibility. You just have to be patient and know that you can do it.

First you need to bend down the "washer" so you can get the bolts off. This washer is actually not a single washer but goes around both bolts. Use a screwdriver and a hammer to bend it down. Before reassembling you need to flatten the washer out with a hammer. Once installed, you will bend it back up. This keeps the bolts from loosening.




Remove the bolts connecting the headers to the engine. On a couple we found a socket we could fit on. On others I had to use a open faced wrench. It was not easy due to no space to work around, but if I can do it, so can you.





There is a gasket, mine stayed on the engine and was in great shape so I didn't mess with it.



The cat is in that bulgy area toward the end of the header pipe.





I took a big screwdriver and hammer and beat around between the cat and the pipe until I could get it out. It took me almost an hour. There was a point where I was really questioning my actions but I was past the point of no return so I just kept on working at it. Needle nose pliers come in handy here as well. Keep a garbage bag nearby to put all the little bits of metal in.





Done... clean the pipe real good of all the leftover bits as best as you can and now on to the other side.





... continued in next post...


Edited by Mol (23/04/15 12:32 AM)

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#269424 - 22/04/15 11:53 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Mol Offline
Just Getting Started

Registered: 28/02/13
Posts: 52
Loc: Okemos, Michigan
Time to wrap the headers. I am lucky to have a friend who used to build customer choppers and has been wrapping pipes for 20 years, He would not let anyone but him wrap my pipes because he wanted it done right.

Wear gloves, if gives you better grip and the wrap can be itchy.





You need a lot of space. You attach the wrap to something really solid and unwind it all (we attached the wrap to my lift way at the other end of the garage). Then you start wrapping applying steady, tight tension the entire time. Darrian Tefft is a master at this. I am so lucky he did this for me for just beer and pizza. (yes, this is our garage)

No, you do not wet the wrap to apply, that just creates a soppy mess.








Darrian, who is a master welder and now teaches welding, used stainless steel welding rod to secure the wrap. This gave it a wonderful Old School look.






... continued in next post...

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#269425 - 23/04/15 12:30 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Mol Offline
Just Getting Started

Registered: 28/02/13
Posts: 52
Loc: Okemos, Michigan
Removing the baffles from the long pipe:

There are three of these "sound dampening" baffles. One solid plate about where the heat shield starts and two plates with holes in them about where the heat shield ends. You'll need two different sizes of hole saw and a 2 foot long extension. We had to jerry-rig our tool together and it got modified as we went and learned. I ended up taping all the joints together with aluminium tape (very strong) to keep the thing more solid and from pulling apart.

When using the hole saw, go slow. You should be able to count the revolutions as it turns. Going any faster just heats up, and hardens, the baffles and dulls the saw. We ruined two saws on two baffles before Darrian explained this to me. After that we used just one saw on the last 4 baffles and the saw is still viable.

I have no good photos of this step, sorry.

The baffles may need a little poking at to get completely out so you'll want to have something long and solid at hand before starting this project. We ended up scrounging up a long metal bird feeder pole. Hey... it worked. Another baffle was really hangy-on and we could not get it totally out so just bent it back as far as we could. It ended up shooting out of the pipe 30 seconds after we started it up for the first time after the mod.

Now put everything back together. Those bolts connecting the header to the engine were a bitch.

Look how smooth the wrap is. It is 1 inch wrap perfectly "locked" together. The more I look at it the more I can't believe how good it looks.



The wrap stinks for awhile after you install it and patinas quite quickly.





I love the new sound. The sound meter on my phone does not indicate the exhaust is any louder, but it sounds more beefy to me. Mostly the sound is deeper and more throaty. It's got some nice balls now.

Power wise, yes, I can feel a difference. The engine is definitely a lot happier. It's hard to explain the difference, but the mods were totally worth it for me.

I'll post up a video for sound soon.


Now, simply a cool photo for your viewing pleasure... This is from a 1800 mile, in one week, trip to a road known as The Dragon, that we took last year, and we will be doing again in just 3 days:



Edited by Mol (23/04/15 12:56 AM)

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#269429 - 23/04/15 01:33 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Squirlz Offline
L - Learner Plates On

Registered: 18/01/13
Posts: 108
I can describe the power difference. I'm her husband. It used to be when you got much over 4000 RPM there were all kinds of cues telling you to upshift. On our shakedown run, I was bombing along , engine singing happily in 3rd gear, and I thought 'I'm going pretty fast for 3rd gear' and I looked down and saw we were doing 5000 RPM! I'm also easily bouncing off the redline when hammering from a stop and getting rubber in 3 gears! We did not anticipate such an improvement.

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#269438 - 23/04/15 01:53 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Richard - Aus Offline

Member of the Inner Circle

Registered: 15/01/12
Posts: 14976
Loc: Perth, WA, Australia
Wonderful write up and very interesting to read. Great sounding results too it appears.
_________________________
Richard
1976 4/4 4 Seater

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#269440 - 23/04/15 02:00 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
fathergoose Offline
L - Learner Plates On

Registered: 21/05/13
Posts: 108
Loc: Charlotte NC. USA
thanks Squirlz, I think I will be doing this to mine, at some point down the road.

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#269445 - 23/04/15 04:24 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
deano Offline

Charter Member

Registered: 12/02/12
Posts: 5336
Loc: Taunton
Totally agree, great write up and interesting results on the power/smoothness improvement.
_________________________
Martin (Deano)

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#269454 - 23/04/15 07:04 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Jays Offline

Member of the Inner Circle

Registered: 08/02/11
Posts: 14003
Loc: Cumbria UK
Great post Mol....just what we need here and in the Club Miscellany...except that they fight shy of publishing it.

Great garage by the way....I'm very envious!!
_________________________
Jays
Former Morgan owner. Gone but hopefully not forgotten!

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#269459 - 23/04/15 07:23 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Roger Tapley Offline
Has a lot to Say!

Registered: 26/09/13
Posts: 1103
Loc: Kent England
That's what I call dedication to driving pleasure well done!
_________________________
RogT Old Git Racer ex 4/4 sand 2013
+4 GDI Royal Ivory 2015
Ford Fiesta ST2

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#269461 - 23/04/15 07:25 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Jays]
Aeroman Offline

Talk Morgan Guru

Registered: 01/09/06
Posts: 7258
Loc: Eton, Berks
+1 - would love to hear the new sound, please post a video.
_________________________
Brian

Morgan SP1 (Rocket Red)
Morgan Plus 8 (Rocket Blue)
Morgan Plus 8 - Moss Box (Black)

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#269464 - 23/04/15 07:38 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Waldemar Offline
Dreiradschubser
Learner Plates Off!

Registered: 29/06/12
Posts: 462
Loc: Tuebingen/D & Carantec/F
wonderful story, thanks a lot wine

Achim
_________________________
4 aircooled cylinders, 7 tires, not waterproof: my M3W Bluebelle and my 2CV Gundel

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#269502 - 23/04/15 09:43 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
wiscos Offline
Talk Morgan Regular

Registered: 26/11/07
Posts: 782
Truly great and very helpful. Of course, many parts of the globe we need to leave the cats in to keep the vehicles legal...

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#269537 - 23/04/15 01:07 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Mi3Wheeler Offline

Talk Morgan Enthusiast

Registered: 03/02/12
Posts: 1662
Loc: Michigan, USA
Good write up, I am excited to hear the difference in person.
_________________________
Charlie, Editor
Morgan Owners Group - Great Lakes

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#269548 - 23/04/15 01:55 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Smaug Offline
Learner Plates Off!

Registered: 21/08/14
Posts: 342
Loc: G.-D. of Luxembourg
Hi Mol,
super review, will probably be my next project...by the way, thanks again for the 'how to do' on the steering comfort kit. I followed that step by step to do mine, was a pleasure having such quality instuctions for that job.

I can only encourage you to continue, I would suggest to give you a steady Topic named something like "M3W tuning? ...ask Mol" or "Mol's quality' how to' " thumbs
_________________________
Cheers,
Georges

M3W, Super Dry edition, sep. 2013 ...called 'DogNose'

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#269557 - 23/04/15 02:19 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
MGDave Offline
Learner Plates Off!

Registered: 08/04/10
Posts: 377
Loc: South Ontario, from Lancashire...
Hi Mol, Interesting article hope we get to hear it soon. I see you're heading down to the Dragon again, we are planning to be there next Thursday on our way to Aiken SC for the MOG40 event, on the return trip will be cruising the Snake. Hope we can meet up if you're still in the area.

cheers
_________________________
Dave
98 +8 Corsa Red
74 MGB Red

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#269563 - 23/04/15 02:31 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
PaulJ Offline

Talk Morgan Addict

Registered: 16/10/11
Posts: 3257
Loc: Somerset, UK
I'm really pleased it worked out and you've improved the car Mol. See, don't take any notice of idiots on public forums - keep doing it your own way.

As a matter of interest, as one or two people have commented, once our cars are three years old, they have to have an annual inspection, which includes a strict emissions test. However, once the test is completed, it is very unlikely that the car will get pulled over for another 12 months, and if the owner has substituted a cat. free pipe, no one would know!
_________________________
Paul
[Beginning to get the best out of the ARP4]

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#269567 - 23/04/15 02:42 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: PaulJ]
Smaug Offline
Learner Plates Off!

Registered: 21/08/14
Posts: 342
Loc: G.-D. of Luxembourg
Speaking '3 years inspection and emission test' by freeing the pipes but leaving the cat in place would it have in incidence on the CO2 emissions? ...and does it affect the noiselevel ( gain not the more bassy sound)? listening

_________________________
Cheers,
Georges

M3W, Super Dry edition, sep. 2013 ...called 'DogNose'

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#269597 - 23/04/15 04:11 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mi3Wheeler]
Squirlz Offline
L - Learner Plates On

Registered: 18/01/13
Posts: 108
Originally Posted By Mi3Wheeler
Good write up, I am excited to hear the difference in person.


We were just thinking at the MSU car show; you haven't even seen her car yet!

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#269610 - 23/04/15 05:43 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Mi3Wheeler Offline

Talk Morgan Enthusiast

Registered: 03/02/12
Posts: 1662
Loc: Michigan, USA
Technically we have seen it at the last two MSU car shows, but every time you had a massive crowd around you.
_________________________
Charlie, Editor
Morgan Owners Group - Great Lakes

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#269612 - 23/04/15 05:45 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
RedThree Offline

Talk Morgan Expert

Registered: 23/10/12
Posts: 2093
Loc: Furry Boots City
Good write up - hadn't thought of tying off the wrap and winding the header towards it. It's amazing just how easy it is to take off and replace the headers after you've done it for the first time though.
As for the cats; I'll be leaving mine in but if I manage to acquire a set of headers that don't have them so that there can be an annual swap for the MOT then...
_________________________
Calum
M3W Photos

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#370729 - 14/06/16 02:59 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Draggin Offline

Talk Morgan Expert

Registered: 13/07/15
Posts: 2500
Loc: Detroit, Michigan, USA
Hypothetically i wonder what size hole saws?
_________________________
kirkusblog.com
2016 M3W John A Prestwich Special

1968 Honda CL175,and 2012 Enfield for sale







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#370750 - 14/06/16 04:14 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
KenShapiro Offline
Has a lot to Say!

Registered: 31/10/15
Posts: 1445
Loc: Baltimore, Maryland USA
Done quite a few wraps. Never heard of or considered removing the headers to accomplish it.
_________________________
The Original Ken
2016 Smith & Stankos Special
10,000 miles.

2014 BMW R9T

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#370764 - 14/06/16 05:04 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: KenShapiro]
Draggin Offline

Talk Morgan Expert

Registered: 13/07/15
Posts: 2500
Loc: Detroit, Michigan, USA
Originally Posted By KenShapiro
Done quite a few wraps. Never heard of or considered removing the headers to accomplish it.

I think they were off to pull the cats, and once off, why not wrap them without the suspension in the way?
_________________________
kirkusblog.com
2016 M3W John A Prestwich Special

1968 Honda CL175,and 2012 Enfield for sale







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#370775 - 14/06/16 05:44 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: PaulJ]
Chris99 Offline

Talk Morgan Expert

Registered: 17/07/13
Posts: 2561
Loc: West Sussex, UK
Originally Posted By PaulJ
As a matter of interest, as one or two people have commented, once our cars are three years old, they have to have an annual inspection, which includes a strict emissions test. However, once the test is completed, it is very unlikely that the car will get pulled over for another 12 months, and if the owner has substituted a cat. free pipe, no one would know!


Great post and the dragon looks an awesome bit of road.

For info, a 3 wheeler does not require a UK MOT emissions test - confirmed by Andymot (our "tame" MOT tester) with a link to the MOT regulations in another thread.



_________________________
Red Leader drive

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#370813 - 14/06/16 08:21 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Draggin]
KenShapiro Offline
Has a lot to Say!

Registered: 31/10/15
Posts: 1445
Loc: Baltimore, Maryland USA
Originally Posted By Draggin
Originally Posted By KenShapiro
Done quite a few wraps. Never heard of or considered removing the headers to accomplish it.

I think they were off to pull the cats, and once off, why not wrap them without the suspension in the way?


I would agree but that's not what he said.
_________________________
The Original Ken
2016 Smith & Stankos Special
10,000 miles.

2014 BMW R9T

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#557012 - 31/01/19 05:58 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
06032 Offline
L - Learner Plates On

Registered: 02/11/18
Posts: 166
Loc: CT, USA
I realize this is an old thread. But I'm curious if removal of the cats and baffles plus the addition of a less restrictive intake, a) essentially results in a 'MMC Stage 1' upgrade, b) if it requires an ECU tune or does the (US-spec) ECU have enough bandwidth to adapt, and c) if a G56 Stage 2 upgrade that includes an ECU tune would be happy layering on top of the 'homemade' Stage 1.

Asked another way, would this mod save the cost of a Stage 1, particularly if the goal is Stage 2 anyway?
_________________________
'17 M3W
'08 Ural Gear Up

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#557120 - 01/02/19 10:08 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
rockabilly john Offline
Talk Morgan Regular

Registered: 19/03/15
Posts: 704
Loc: London uk
Don't you need the Cam upgrade to accomplish this?

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#557166 - 01/02/19 12:48 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: rockabilly john]
Chris99 Offline

Talk Morgan Expert

Registered: 17/07/13
Posts: 2561
Loc: West Sussex, UK
There's a bit of inconsistency in the stages depending on whether you are talking MMC, G56 or Krazy Horse. Basically the standard ECU should be OK until you upgrade to the 569 cams.

MMC/G56:

Stage 1: Exhaust and air filter, fine with standard ECU
Stage 2: Add upgraded cams and ECU

KH:

Stage 1: Exhaust and air filter, retain standard ECU
Stage 2: Add ECU and dyno tune
Stage 3: Add cams and dyno tune
Stage 4: Add 128ci big bore kit, roller rockers, ported cylinder head, throttle bodies, high flow injectors and dyno tune
_________________________
Red Leader drive

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#557182 - 01/02/19 01:26 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: rockabilly john]
06032 Offline
L - Learner Plates On

Registered: 02/11/18
Posts: 166
Loc: CT, USA
Originally Posted By rockabilly john
Don't you need the Cam upgrade to accomplish this?
Originally Posted By rockabilly john
Don't you need the Cam upgrade to accomplish this?


Correct. Which includes an ECU reflashed for the cams, so wouldn't it assume the engine is breathing better too and factor that increased air flow into its equation?

So if the goal is Stage 2, why not just help the engine breath better on your own? If the noise proves unacceptable, buy a set of Stage 1 pipes. Does this make sense? I'm trying to figure out why a MMC Stage 1 is worth $2k.....
_________________________
'17 M3W
'08 Ural Gear Up

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#557211 - 01/02/19 03:20 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Something to keep in mind with upgrades is that while the factory "locked" ECU is adaptive to a large degree, the adaptive fuel/spark maps it creates are lost when the ECU is disconnected from power i.e. the battery is disconnected. It will of course "re-learn" the current engine set up on re-connection, but that takes some time/miles.

The "unlocked" ECU gives you the option of merging the "learned" adaptive maps with the baseline map, thus creating a new baseline map stored in non-volatile memory. Adaptation to changing conditions still occurs, but referenced to the new baseline.
_________________________
Steve
2012 M3W #458
SW Iowa


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#557214 - 01/02/19 03:28 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
M3W55 Online   content
L - Learner Plates On

Registered: 19/07/18
Posts: 184
My Stage 1 is being done at the factory while it is there for other work. MMC insist on an ECU reflash for that. Is there any notable benefit, since it seems that most Stage 1 adopters on TM seem to get by without touching the ECU?

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#557224 - 01/02/19 04:06 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
Chris99 Offline

Talk Morgan Expert

Registered: 17/07/13
Posts: 2561
Loc: West Sussex, UK
Originally Posted By Bitsobrits
Something to keep in mind with upgrades is that while the factory "locked" ECU is adaptive to a large degree, the adaptive fuel/spark maps it creates are lost when the ECU is disconnected from power i.e. the battery is disconnected. It will of course "re-learn" the current engine set up on re-connection, but that takes some time/miles.


I've used a battery disconnect when not using the car since new and never had any issue with the ECU "forgetting" the adaptive settings - either when standard, Stage 1 or, as now, KH stage 3.

I ran the standard ECU with the MMC Stage 1 and switched to a KH unlocked ECU when I had the cams upgraded.
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Red Leader drive

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#557244 - 01/02/19 04:40 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: M3W55]
06032 Offline
L - Learner Plates On

Registered: 02/11/18
Posts: 166
Loc: CT, USA
Originally Posted By M3W55
My Stage 1 is being done at the factory while it is there for other work. MMC insist on an ECU reflash for that. Is there any notable benefit, since it seems that most Stage 1 adopters on TM seem to get by without touching the ECU?


After hearing mixed messages on this topic between the forum and dealer, I contacted the factory in Oct. and was informed that an ECU flash was 'most probably' unnecessary for Stage 1.

In contrast, my US dealer feels its 'likely' necessary due to the already lean nature of the mixture to meet DOT requirements but not 100% sure. The only consensus seems to be that if you don't reflash and the ECU triggers a fault code, it's time to reflash.

Personally, if I weren't interested in Stage 2 (cams) and sure I'd hold firm at MMC Stage 1, I'd take the reflash to be sure. But at the absurd quoted $2k for a set of Stage 1 pipes, filter and minimal ECU tune, I can't help wonder if the true value play is the path I'm considering.

BTW, my battery is disconnected for the winter. I would imagine that once reconnected with a homemade Stage 1, it wouldn't take long to discover if this theory holds. Unfortunately, I haven't heard that Stage 1's are shipping yet and I'm impatient.
_________________________
'17 M3W
'08 Ural Gear Up

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#557258 - 01/02/19 05:07 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Chris99]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
[/quote]
I've used a battery disconnect when not using the car since new and never had any issue with the ECU "forgetting" the adaptive settings - either when standard, Stage 1 or, as now, KH stage 3.
[/quote]

That the adaptive maps are stored in volatile memory and lost upon power disconnect is not conjecture on my part or internet lore-I took that information from the S & S Protune manual page 87 paragraph 9.5.

In your case I would imagine the adaptation was slight enough you did not notice the change and/or the new maps built quickly enough to mask the change.

In my own car, after a change to a cat-less straight through exhaust, the change from adaptive maps to baseline map after using the battery disconnect was quite noticeable, and it took 15-20 miles of running for the engine to return to its previous happy self. Merging the maps eliminated this. In all I did three maps merges after 100+ mile variable condition drives. The last one showed minimal change from the 2nd one, so I've stopped there. The Protune software allows you to visually and numerically compare maps, assuming you saved your previous versions


Edited by Bitsobrits (01/02/19 05:15 PM)
_________________________
Steve
2012 M3W #458
SW Iowa


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#557300 - 01/02/19 07:29 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
kankeL Offline
L - Learner Plates On

Registered: 12/08/09
Posts: 177
Loc: Rio Del Mar, CA
Steve, did you purchase the ECU from Garage56? Was the installation straightforward?
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2016 M3W, Army Green Matte/Tan Leather

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#557366 - 01/02/19 09:57 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: kankeL]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Originally Posted By kankeL
Steve, did you purchase the ECU from Garage56? Was the installation straightforward?


Yes, from G56, with the fan kit upgrade installed, even though I don't have the fan kit yet. While I wouldn't call the installation easy, it was straightforward. Straightforward because you just unplug it (battery disconnected!) and remove the two mounting screws. It's not easy because getting to the two mounting screw involved working around tightly grouped wiring, and the connector I was finally able to remove from underneath the dash after removing the center under dash trim pad. I would also say a ball end hex key is required for the mounting bolts due to angle constraints. Seems the ECU is the first thing they mount on the chassis before everything goes on! After installation my speedo didn't work, because in my struggle I had dislodged a wire in the connector from the front wheel sensor. Was easy to fix (just push it home) but took a bit of internet searching to find some clues on why speedos stop working, and therefore which wires to examine.

It occurred to me at the time I should build a small sleeve/box to mount that would allow the ECU to just slip out. Didn't want to take the time.

The port for plugging in the computer cable is fairly accessible, but has very small screws you must not lose. During my driving/tuning weekend I left the cable plugged in with a cap over the computer end when not in use. Kept the risk for screw loss to a minimum.
_________________________
Steve
2012 M3W #458
SW Iowa


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#557383 - 01/02/19 10:46 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
kankeL Offline
L - Learner Plates On

Registered: 12/08/09
Posts: 177
Loc: Rio Del Mar, CA
Originally Posted By Bitsobrits
Originally Posted By kankeL
Steve, did you purchase the ECU from Garage56? Was the installation straightforward?


Yes, from G56, with the fan kit upgrade installed, even though I don't have the fan kit yet. While I wouldn't call the installation easy, it was straightforward. Straightforward because you just unplug it (battery disconnected!) and remove the two mounting screws. It's not easy because getting to the two mounting screw involved working around tightly grouped wiring, and the connector I was finally able to remove from underneath the dash after removing the center under dash trim pad. I would also say a ball end hex key is required for the mounting bolts due to angle constraints. Seems the ECU is the first thing they mount on the chassis before everything goes on! After installation my speedo didn't work, because in my struggle I had dislodged a wire in the connector from the front wheel sensor. Was easy to fix (just push it home) but took a bit of internet searching to find some clues on why speedos stop working, and therefore which wires to examine.

It occurred to me at the time I should build a small sleeve/box to mount that would allow the ECU to just slip out. Didn't want to take the time.

The port for plugging in the computer cable is fairly accessible, but has very small screws you must not lose. During my driving/tuning weekend I left the cable plugged in with a cap over the computer end when not in use. Kept the risk for screw loss to a minimum.


Thanks! Will order myself a new ECU wink
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#557391 - 01/02/19 11:57 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: 06032]
Chris99 Offline

Talk Morgan Expert

Registered: 17/07/13
Posts: 2561
Loc: West Sussex, UK
Originally Posted By 06032
But at the absurd quoted $2k for a set of Stage 1 pipes, filter and minimal ECU tune


This would include a new, unlocked ECU as the standard one can only be reflashed with a MMC file.

So the $2k probably breaks down to approx $800 exhaust, $800 ECU and $400 air filter and fixings
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#557482 - 02/02/19 04:57 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
2Sharp Offline
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Registered: 20/10/16
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When you install your new ecu I would suggest ditching the screws in favor of Velcro. Unfortunately I figured this out after fitting the new ecu.

I have not played around with the software but likely need to to merge the maps.

It is hard to tell what did what but the engine is transformed to me as the power is much more linear and the below 3k feels much more lively. I had the factory stage 1 which was good but much better now.

It is a shame we don’t have a tuner like the two options in the UK in the US

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#557657 - 03/02/19 01:15 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Chris99]
06032 Offline
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Registered: 02/11/18
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Loc: CT, USA
Originally Posted By 2Sharp
When you install your new ecu I would suggest ditching the screws in favor of Velcro. Unfortunately I figured this out after fitting the new ecu.

I have not played around with the software but likely need to to merge the maps.

It is hard to tell what did what but the engine is transformed to me as the power is much more linear and the below 3k feels much more lively. I had the factory stage 1 which was good but much better now.

It is a shame we don’t have a tuner like the two options in the UK in the US


Originally Posted By Chris99
Originally Posted By 06032
But at the absurd quoted $2k for a set of Stage 1 pipes, filter and minimal ECU tune


This would include a new, unlocked ECU as the standard one can only be reflashed with a MMC file.

So the $2k probably breaks down to approx $800 exhaust, $800 ECU and $400 air filter and fixings


Not exactly. The quote includes sending my own ECU back to MMC for a reflash. What makes more sense to me is $1200 for Stage 1 (pipes and filter alone) plus the components of Stage 2 with the unlocked ECU all in one go. Doesn't make sense to pay for the ECU twice. Am I missing something?
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#557860 - 04/02/19 01:44 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
rockabilly john Offline
Talk Morgan Regular

Registered: 19/03/15
Posts: 704
Loc: London uk
Hi Molly, what wrap did hoy use?
Thanks.
John.

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#560893 - 19/02/19 07:11 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Draggin Offline

Talk Morgan Expert

Registered: 13/07/15
Posts: 2500
Loc: Detroit, Michigan, USA


Edited by Draggin (19/02/19 07:11 PM)
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#560970 - 20/02/19 12:52 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Taffmog Offline
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Registered: 22/09/10
Posts: 1541
Loc: Wales
Great post Mol and brilliant pics, I think I’ll have a go on mine soon....

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#561463 - 21/02/19 09:43 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Draggin Offline

Talk Morgan Expert

Registered: 13/07/15
Posts: 2500
Loc: Detroit, Michigan, USA
Have a look at my method, I do not remove the pipes
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#561827 - 23/02/19 08:09 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
LightSpeed Offline
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Registered: 18/02/19
Posts: 249
Loc: Port Orchard Washington, USA
Here is a newbie question, how do you clean the wrapped headers?
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#561972 - 24/02/19 07:30 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: LightSpeed]
06032 Offline
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Registered: 02/11/18
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Loc: CT, USA
Originally Posted By LightSpeed
Here is a newbie question, how do you clean the wrapped headers?


Replace the wrap? Re-spray with high-temp silicone? Start with a dark color? Not much experience with mine yet but I doubt it will take a scrubbing. Not that hard to replace.
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#562018 - 25/02/19 02:39 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
LightSpeed Offline
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Registered: 18/02/19
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Loc: Port Orchard Washington, USA
06032
I understand one reason for the wrap is to protect the turn signal lamp from excessive heat, but is the only other reason to have it is for appearance?
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#562127 - 25/02/19 05:33 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: LightSpeed]
Michael H Offline
Has a lot to Say!

Registered: 29/04/13
Posts: 1159
Loc: Southern Vermont
Originally Posted By LightSpeed
06032
I understand one reason for the wrap is to protect the turn signal lamp from excessive heat, but is the only other reason to have it is for appearance?


And that's about it! I've tried wrapping the headers with different materials and abandoned all of them. It keeps the heat in the pipes when cooling them would be much better. Wraps were originally used inside engine compartments to keep that space cooler. They were not designed for external use. Mine all degraded over time, became brittle and came off in pieces. Getting wet occasionally probably did not help, either.
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#563066 - 02/03/19 02:58 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
I've recently had my headpipes silver ceramic coated. Not real wild about their somewhat "blingy" appearance, but will see how they age once the weather breaks and we can get some heat and miles on them.
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#563068 - 02/03/19 04:36 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
kankeL Offline
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Registered: 12/08/09
Posts: 177
Loc: Rio Del Mar, CA
Pictures, please? 😎
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#563177 - 02/03/19 04:24 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Somewhat visible here-I'll take better photos later today.

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2012 M3W #458
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#563183 - 02/03/19 05:04 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
LightSpeed Offline
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Registered: 18/02/19
Posts: 249
Loc: Port Orchard Washington, USA
Nice idea!

I too think getting heat out of the pipes rather than holding it into the pipes is a better idea and if a person wants to protect their turn signal lamps I suspect a heat shield for each lamp could be made out of aluminum tubing.
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#563196 - 02/03/19 06:06 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
britmog Offline
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Registered: 13/12/17
Posts: 175
Loc: Colorado, USA
Here’s how they work—ceramic coatings and exhaust wraps help contain the gaseous heat within your exhaust pipes. This causes the gasses to heat up and expand. Since the exhaust gas is trapped within the system, it expands the only direction it can—out of the tailpipe. As a result, exhaust flow is boosted, allowing a rush of fresh air to enter the engine’s cylinders, increasing horsepower. Both ceramic coated headers and exhaust wraps improve horsepower, however, ceramic coating is better than exhaust wrap as it does not trap moisture although more costly. The ceramic coating should dull over time.


Edited by britmog (02/03/19 06:10 PM)
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#563213 - 02/03/19 07:30 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Here's a more representative photo of the ceramic coated headpipes. From my experience with this particular coating product from my local powder coater, it takes thousands of miles over several years to show appreciable dulling. On my occasionally tracked Lotus Elan (so much more high rpm running) the dulling effect occurred more rapidly than on my more sedately driven E-type. Both of those cars have the ceramic over stainless steel tubular manifolds, so similar to the Morgan.

These pipes have only a few minutes of idling time on them to check for leaks. It will be a couple of months before the snow is gone and roads are clear enough for a real run in. frown

One of the downsides to coating the head pipes is the color mismatch with the rest of the stainless exhaust. The ceramic coating is closer to polished aluminum (whiter) than the more bluish-brown of the stainless. The woven mesh of the flex couplings were simply masked off during the coating process, btw.

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#563216 - 02/03/19 07:45 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
kankeL Offline
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Registered: 12/08/09
Posts: 177
Loc: Rio Del Mar, CA
Looks very nice, Steve! 👍
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#563259 - 03/03/19 02:34 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
LightSpeed Offline
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Registered: 18/02/19
Posts: 249
Loc: Port Orchard Washington, USA
+1 , very nice looking! Can I assume that it could be a different color if desired, although i like what you have done.

Is it easier to clean than stainless?
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#563360 - 03/03/19 01:58 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
06032 Offline
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Registered: 02/11/18
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Loc: CT, USA
My takeaway: The caveat to ceramic or wrap is that increased heat and expansion is counter-productive without creating a clear pathway for escape in an already restrictive system. Hence removal of cats/baffles.

A corollary I've heard is that the temperature at the tip of the exhaust should be hot, such that only one finger's width can tolerate the heat. And that's how you'll know if the exhaust is flowing freely. Maybe just an old 'gear head's' tail....
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#563387 - 03/03/19 03:49 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
06032 Offline
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Registered: 02/11/18
Posts: 166
Loc: CT, USA
Originally Posted By Bitsobrits
Somewhat visible here-I'll take better photos later today.



Steve - is this a screened vented cover? Source info? Sure beats wedging it open at the bottom.
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#563415 - 03/03/19 06:23 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Answering a couple of questions:

The ceramic coating is available in a few colors, including black, which vary by manufacturer. The powder coater you use to do the coating will impact the choices available to you.

The coating is so much easier to maintain than bare stainless, which is why I used it on my other cars. No bluing, no discoloration, no polishing. Basically you do nothing but wash it once in awhile to remove bugs and other detritus.

As for the screened cover, at the moment it is cosmetic only. My intent is to find a suitable waterproof filtering medium to insert under the perforated cover, then place holes in the S&S emblem area. The pre-perforated cover is 1/16" thick stainless I bought online for a few dollars and has the edges peened over to give it the 3 dimensional look.
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#563435 - 03/03/19 07:40 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Bitsobrits]
06032 Offline
L - Learner Plates On

Registered: 02/11/18
Posts: 166
Loc: CT, USA
As for the screened cover, at the moment it is cosmetic only. My intent is to find a suitable waterproof filtering medium to insert under the perforated cover, then place holes in the S&S emblem area. The pre-perforated cover is 1/16" thick stainless I bought online for a few dollars and has the edges peened over to give it the 3 dimensional look."

Ahh...clever.

I wonder how waterproof the material needs to be if at present its deemed ok to wedge the entire bottom open!? I'm trying to think of a fabric that blocks water and particles but breathes: a replaceable section of breathing mask material, cotton tent fabric, landscape fabric, dense sponge?
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#563444 - 03/03/19 08:45 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
Bitsobrits Offline
Just Getting Started

Registered: 16/02/18
Posts: 89
Loc: SW Iowa, U.S.A.
Waterproof only so it doesn't rot. Needs to allow some amount of air but no grit. So something simple and inexpensive. Perhaps just a bit of stainless steel wool.
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2012 M3W #458
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#564697 - 08/03/19 06:37 PM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
06032 Offline
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Registered: 02/11/18
Posts: 166
Loc: CT, USA
Finally...FINALLY....got a chance to go for a long ride (very comfortable at 32F and snow on the ground) to try out the combo of a baffelectomy, stealth intake and Ohlins (only the front so far).

Result: Louder only when you'd expect it to be, crisper throttle response, much happier throughout the rev range, do need to watch the RPM's now.....and the Ohlins, oh my, the Ohlins give the front end a lightness beyond my expectations. Very noticable. Happy, happy!
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#564788 - 09/03/19 02:12 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: 06032]
LightSpeed Offline
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Registered: 18/02/19
Posts: 249
Loc: Port Orchard Washington, USA
Tell me about the Olin shocks, what model are they?
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#565352 - 11/03/19 12:52 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: LightSpeed]
06032 Offline
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Registered: 02/11/18
Posts: 166
Loc: CT, USA
Originally Posted By LightSpeed
Tell me about the Olin shocks, what model are they?


Custom spec. If you search on this site, you'll find a data sheet and contact at Ohlin/U.S. You'll need to confirm a few measurements.
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#565353 - 11/03/19 12:54 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
LightSpeed Offline
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Registered: 18/02/19
Posts: 249
Loc: Port Orchard Washington, USA
Thanks, found it.
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#565354 - 11/03/19 01:14 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
rockabilly john Offline
Talk Morgan Regular

Registered: 19/03/15
Posts: 704
Loc: London uk


Will this do?
These are not mine, but have been uploaded at some time by another M3W member.
John.

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#565355 - 11/03/19 01:19 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
rockabilly john Offline
Talk Morgan Regular

Registered: 19/03/15
Posts: 704
Loc: London uk
lightspeed, pm sent.
john

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#565412 - 11/03/19 11:24 AM Re: Wrapped headers, removed cats and exhaust baffles [Re: Mol]
06032 Offline
L - Learner Plates On

Registered: 02/11/18
Posts: 166
Loc: CT, USA
If you're a suspension nut, you'll appreciate this 'yellow' upgrade. I swapped my OE' Spax units after only 300 miles.
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