DIY Network

1965 Mustang Restoration: Installing Performance Headers The Mustang's stock exhaust manifold gives way to ceramic-coated Hooker headers for improved performance and a few more horses. From "Classic Car Restoration" episode DCR-505

The new exhaust system will improve flow of exhaust gasses and boost engine performance.

Steve Magnante, host of DIY's Classic Car Restoration, continues the what he calls a "resto-mod" on our 1965 Mustang project car — a restoration with modifications and upgrades that will make the car even better and more enjoyable than it originally was.

In this project, Steve improves the original exhaust system by installing a system with larger pipes and high performance mufflers. He begins by removing the stock cast-iron exhaust manifolds and installing new ceramic coated Hooker headers. These will improve the flow of exhaust gasses and thus improve engine performance.

The basic steps in this part of the restoration as seen in this episode of Classic Car Restoration, as well the tools and materials required, are summarized below.

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	New header bolts and header gaskets for the exhaust system upgrade
	Steve with the new Hooker headers prior to installation

Tools and materials used in the exhaust system upgrade:

hooker headers (1-7/8" diameter)
new exhaust system
2 performance mufflers
mounting hardware
penetrating oil
full set of wrenches/sockets
H-inlet pipe section
full tailpipes
jack and jack stands
safety equipment

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, don't rely solely on a jack to support the weight of a vehicle. When using a jack to access or work beneath a vehicle, always use jack stands for support. Make sure that the jack and stands that you use are rated for the weight and type of your vehicle.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

	Steve removes the old exhaust manifold.
	The old manifold and tailpipes, removed

Steps:

• Exhaust manifold bolts are notorious for being rusty and stubborn to remove, so be sure to use penetrating oil on them if you need it.

  Tip: If you apply penetrating oil a few days in advance, the bolts should come out easily.

• When installing headers, it's a good idea to have some extra hands. One person goes under the car and holds the header in place so someone else can secure it from above.

• Insert the header gasket in between the cylinder head and header flange. To make this easier, put a long bolt in the front and back of the header flange (where the slots are) and then drop the gasket in place.

• Temporarily install the longer bolts from the stock manifolds at the flange ends to hold the gasket on.

• The gasket goes in and hangs on the long bolts. Carefully push the header into place.

• The header bolts and washers are installed and tightened down just to snug until all of them are in.

• Remove the temporary long bolts at the ends of the header.

• Install the new short bolts and tighten them down.

• After the passenger side headers are on, install the drivers side. Then the car is ready for the new exhaust system install.

RESOURCES :

Special resources for DIY's Classic Car Restoration 500 series: 1965 Mustang

Mustang Club of America
www.mustang.org

Mustang Central
vintage Mustang parts
www.mustangcentral.com

Motorbooks Publishing
www.motorbooks.com

Class-Tech-Cars
www.class-tech-cars.com

Holley Performance Products
www.holley.com

Flowmaster Exhaust Products
www.flowmastermufflers.com

Genuine Hot Rod Hardware
www.genuinehotrod.com

Revelation Racing Supply
www.rrs-online.com

National Parts Depot
www.npdlink.com

Classic Auto Air
www.classicautoair.com

Pertronix Performance Products
www.pertronix.com

Stainless Steel Brake Corp.
www.ssbrakes.com

Painless Performance Products
www.painlessperformance.com

Loctite Products
www.henkel.com

Paintucation
www.paintucation.com

Dupli-Color Paints
www.duplicolor.com

Norton Abrasives
www.nortonabrasives.com

Dremel Tools
www.dremel.com

Classic High Performance Audio
Product: audio equipment

Direct Source
www.the-direct-source.com
Product: stereo electronic equipment

Dakota Digital Instruments
www.dakotadigital.com
Product: digital dashboard

Mustang Project
www.mustangproject.com
Product: LED sequential taillight system

Memory Lane Collector Car Dismantlers
vintage and salvage auto parts
www.oldautoparts.com