Budget C5 Headers - Lifting The Corvette Tax

The passenger-side exhaust-manifold bolts are removed...

...and the manifold is extracted and set aside. The procedure is then repeated on the driver's side.

TSP's long-tube headers are mandrel-bent from 16-gauge steel and equipped with heavy-duty 31/48-inch flanges and 31-inch primaries. Designed as off-road headers for '97-'04 Vettes, they have O2-sensor provisions (but no AIR provisions) and sell for $579.99. An AIR version is in development and should be available by the time you read this. Included with all TSP headers are new O2 extensions, GM exhaust-manifold gaskets, and a new dipstick that updates '97-'00 vehicles to the '01-'04 cylinder-head-mounted design.

After placing an oil pan under the oil filter, the filter and starter are removed to free up space.

After lowering the car, the driver- (shown) and passenger-side headers are carefully maneuvered into position.

The stock exhaust-manifold bolts are cleaned up with a wire wheel, and their threads are coated with anti-seize compound. A front header bolt is threaded in a few turns, and then the gasket is positioned so that a back header bolt can be threaded into position. This procedure is repeated on the passenger side, after which the car is again raised.

Next, the supplied O2 extensions are connected. Once the wires are extended, anti-seize compound is placed on the threads of the O2 sensors. Care must be taken to ensure that no compound gets on the ends of the sensors.

The car is lowered, and the four remaining bolts on the passenger-side header are threaded in. Bolts should be tightened in increments, starting with the centers and working outward. Once the bolts are snug against the header, they are tightened to 18 lb-ft (and no more) with a torque wrench. The driver's-side header is then installed in a similar fashion.

For customers who prefer to retain their factory mid-pipe, TSP carries headers packaged with connection pipes for $649.99. The pipes measure 3 inches on the header side but drop down to 2 1/2 inches to connect to the stock hardware. Although the stock mid-pipe has to be cut, the process is relatively simple, and all required clamps are included.