Stainless Works' long-tube...
Stainless Works' long-tube LT1 C4 headers are crafted from mandrel-bent 304 stainless steel and feature built-in air-tube and O2-sensor bungs. Ours came with the optional Random Tech high-flow catalytic converters.
This month marks the reappearance (again) of our '96 LT1 Corvette, a car whose halting progress toward the goal of achieving C5 Z06-quality acceleration without pauperizing its owner has been unfolding seemingly since the days of the optional whitewall. To date, the Polo Green coupe has been the beneficiary of a number of cost-effective modifications, ranging in scope and difficulty from a comprehensive valvetrain upgrade to a quick-and-easy (and surprisingly effective) ultrasonic fuel-injector cleaning.
In this installment, we'll tackle the car's exhaust system. Given that replacing the OEM rear-section exhaust setup is typically one of the first alterations made by any mod-inclined Vette owner, you may be wondering what took us so long to reach this point. The answer has to do with the limitations imposed by a dwindling C4 aftermarket and our longstanding predilection for covering only the latest, most notable performance hardware whenever possible.
While converter-back systems for the C4 abound, long-tube headers-critical for making maximum power in a high-output Gen II engine- are about as common as yeti sightings in Cozumel. When we learned late last year that Stainless Works was cooking up a full, header-to-tips system for the '92-'96 model, we signed on to be the first to install and test the new parts. The highlights of the daylong job-performed once again by the inveterate Vette nuts at AntiVenom EFI in Seffner, Florida-follow, along with some subjective impressions and post-install dyno results.
Complementing the headers...
Complementing the headers was this converter-back exhaust system, which came to us with dual 21/2-inch intermediate pipes, an X-style crossover, a pair of polished tips, and a full complement of hangers. Like all SW exhaust parts, it's covered by a limited lifetime warranty.
After more than 77,000 miles...
After more than 77,000 miles of use, our '96's original exhaust system resembled something left over from a marine-salvage operation. Worse, it was starting to leak.
AntiVenom tech Will Edgar...
AntiVenom tech Will Edgar begins the job by unbolting the stock exhaust hardware, starting at the cats and moving rearward.
With all the bolts liberated,...
With all the bolts liberated, Edgar and shop honcho Greg Lovell remove the entire system as one piece.
Here's the old factory setup...
Here's the old factory setup as laid out on the ground behind the shop. Note the large, sound-attenuating resonator positioned ahead of the dual mufflers.
A comparison of the Random...
A comparison of the Random Tech cat (foreground) and the OEM unit reveals a marked contrast in design efficiency. The new piece is smaller, lighter, and cleaner-looking than the stocker. It also flows better and radiates less heat.
With the rear portion of the...
With the rear portion of the exhaust removed, Edgar drops the car and moves on to the job of pulling the cast-iron factory manifolds.
Now sans manifold, the LT1...
Now sans manifold, the LT1 shows off its traditional D-shaped exhaust ports.
If you're following along...
If you're following along at home, you'll need to source your own gasket...