C5 Corvette Performance Build - C5 On A Shoestring

SLP's tuned-length long-tube headers are mandrel-bent to maximize flowand constructed from 0.055-inch wall-thickness 409 stainless steel. Theyfeature 13/4-inch primary tubes flowing into a 3-inch four-into-onecollector. They're fully compatible with all stock emissions-controlequipment and use OEM flanges for proper bolt retention.

To access the exhaust manifolds, we needed to remove the battery shroudand battery, the plastic engine covers, the plug wires, the ignitioncoil packs, the serpentine belt, the A.I.R. tubes, and the dipsticktube.

Prior to pulling the exhaust, we had to remove the oxygen-sensor leadsand clips. After that, we took down the pipes and tips, then dropped themufflers. To ease the removal of the mufflers, we loosened and moved therear stabilizer bar.

Here's a comparison of a stock exhaust manifold and one of the SLPheaders. We were extremely impressed with the quality of the welding andthe construction of the SLP units.

We located the T-shaped junction in the wiring harness at the rear ofthe passenger-side cylinder head. Next, we removed enough of theprotective tape to allow us to take off about an inch of the plasticloom that runs down to the starter. After disconnecting the wires andremoving the starter, we extended each of the wires to approximately 14inches. This allowed us to run them through the rear header-tube loop toprevent them from being burned.

Next, we installed an 8-inch length of heat-shield tubing over thestarter wires and the positive battery cable.

SLP supplies the necessary header-installation hardware, including thecrankshaft-position-sensor extension lead and the heat-shield tubing forthe starter and battery leads. We had enough tubing left over to placesome over the engine-oil-sensor lead.

We had to unbolt the engine mounts and raise the engine slightly toinstall the headers. The passenger side went in easily, but the driverside was a bit more challenging.

This photo shows the passenger-side header bolted in place, with thewires run through the rear header-tube loop.

At this point, we've reinstalled the spark plugs and plug wires. It'simportant to note the positioning of the wires so they aren't damaged bythe headers. We've also reinstalled the coil packs, the dipstick tube,and the A.I.R. tube.

Installing the headers on the driver side required lifting the engine ashigh as possible, unbolting the intermediate shaft at the steering box,and moving it to one side. We reused the factory manifold bolts toinstall the headers.

The 3-inch H-pipe completes the connection between the catalyticconverters and the rear-section exhaust system. It's equipped with atrue 3-inch balance tube (the stock connection measures only half thatat its narrowest point).

SLP's H-downpipe connects with stock, SLP, or aftermarket catalyticconverters. The pipes are made of 3-inch 409 stainless steel and use a2.5-inch balance tube for optimal flow characteristics.

SLP's catalytic converters use a high-flow design and fit perfectly withSLP's downpipe and intermediate pipes.

At this point in the installation, the headers, H-downpipe, and catshave all been bolted in place.

Here, Eddie Nenninger routes the tailpipes over the rear-axle assembly.You may find it easier to loosen and move the rear stabilizer bar tofacilitate the pipe installation.

Here's the completed installation from headers to tailpipes. Compare thedesign of the SLP system with the factory exhaust pictured earlier. SLPdid a superb job engineering its system to fit the C5.

The C5 Power-Flo system has an industry-exclusive cast-aluminum tip thatwas styled by a member of GM's C5 design team. Our system slid directlyinto the factory hangers with no modifications needed.

It's always a good idea to trial-fit the mufflers and exhaust tip andalign them before bolting everything into place.

Here, we've installed the mufflers and tip. Notice the factory mufflerheat shields and how small the SLP mufflers are in comparison. They'realso considerably lighter than their stock counterparts.

The exhaust tip has a unique shape that conforms to the Corvette'srear-fascia opening. If you prefer a more conventional look, SLP alsooffers the Power-Flo system with twin round tips.

Here's the completed SLP Power-Flo system. It should take someone withaverage mechanical skill less than three hours to install. A second setof hands is required, and a lift is strongly recommended.