Hello,

I could really use some help from the experts on this board. I'm currently home visiting my brother, he owns a '91 Camaro with the 305 (code E) engine with a single cat. He needs/wants to get a new full exhaust system put on his car, we're talking headers to tailpipe. Since he is clueless when it comes to cars, and I'm pretty mechanically inclined I offered to do the research, buy and install the parts for him. The problem is, I work on Subaru's which I'm finding out is a world apart from Camaro's. My entine knowledge of your cars comes from reading through this board. My brother is also on a limited budget ($600 or less). So going mainly off a very informative post by Gunny Highway, this is what I've pieced together:

Headers - Flowtech Headers and Y-pipe ($236)



Cat - Catco High Flow Cat ($101)

Picture here

Exhaust - Dynamax Cat Back ($169)

That puts the total = $506

That leaves me with about a $100 to use for shipping charges, gaskets, and anything else I may need. What I need to know is whether these pieces will all fit together on his car, what else do I need? Any little thing you can think of, I'm lost when it comes to v8 power Gunny Highway mentioned that I'd need a new serpentine belt, but I couldn't find the part number he mentioned, can someone help with that? And where can I find the gaskets I need, how many do I need, etc. Any help with this will be very much appreciated. Thanks in advance

-Chad.

 

Typically, the headers will come with the gaskets you will need as far as flange-to-head and header to y-pipe goes. I don't believe you will have to dissassemble any other parts that require gaskets during installation. You might consider getting a sawsall (electric saw) or cutting torch, as the slip joints never come apart as easilly as they went on. A wire feed welder and a lift are handy, but you don't need them. A good jack and stands are absolutely essential, and if you have the cash, go for some copper header gaskets. They tend to seal tighter and prevent leaks much better than the composite gaskets that come with the kit. Also think about painting the headers with high-temp header paint, as the paint that is on there from the factory usually burns off.

If you are looking to get a real cheap system, instead of quality, look at JC whitney, they have headers and exhaust systems for the thirdgens cheaper than any I have ever seen. This comes with the given facts that it will not last as long or sound as nice as the better systems.
Hope this helps,

 

What I really need to know is if these parts will bolt together correctly? Or do they need to be welded together? Is headers, y-pipe, cat, and cat-back all I need to complete the exhaust? Where can I find copper gaskets and this header paint you mentioned. Thanks

-Chad.

 

From looking at the part #s you provided, I believe everything should bolt together. The only thing I'm not sure about is the cat/I-pipe flange. there were a bunch of different ones, depending on the engine. If you order stuff for the same enging ie 305HO, 5.0TPI, etc, they'll all fit together.

You should be able to get everything bolted toether just fine, but I suggest taking the car to a muffler shop to get the joints tack-welded, especially on the slip joints in the y-pipe, the intermediate pipe, and where the outlets hook on to the muffler. It'll help keep things from working loose over time.

 

You can get the gaskets from your local parts store, Mr Gasket has some of the most common ones, they will run you $40-50. The paint I use is the High Temp Engine enamel from Duplicolor, which is also available at your local parts store.

I would highly suggest that you have all the fittings that are permanent welded, but all of it should bolt together.

 

Only other consideration is AIR fittings - Does his car still have the AIR? Is there smog emissions? If so, he may need the headers with A.I.R. fittings, and a an AIR cat to match.