TWE EL Headers

[DLC]

After one month of waiting for them to be shipped, they got here this morning:



It's in pretty good shape, not "mint", but it looks like it's done 6000 miles in New Jersey.

I have better pics on my camera, but it's a Fuji, uses xD media and I forgot my cable...

I'm impressed by the quality of the welds. It's also stainless, so it's very, very light. I'm sure the Borlas are similar, but I'm still impressed at the weight of the thing.

Should be a bolt-in job, though I've been told to change my transmission fluid beforehand if I need to, because it blocks the drainplug.

[DLC]

Some more pics, before, during and after install:






Nice welds, nice, smooth bends.



exhaust leak on the Borlas




excellent collector design


pesky trans drain plug




It sounds...different, but in a good way. Matt can relate to the way it sounds, though I'm sure it's different with his Cobb EL setup and cat/muffler selection. It sounds much more like a sports car and less like "a 50-gallon drum full of rubber balls, rolling down a hill".

I might have to remove more material from the transmission drainplug, but it seems to be ok for the moment. There are other plugs that are shorter or flush that I may have to investigate.

I like the sound. It's much quieter at idle too, for better or worse.

[BAC5.2]

So you were disappointed in the sound with the Borla's?

I've been pretty intrigued by the OBX header. Looks like a COBB knock-off, and Pat Olsen did a dyno test showing very very impressive numbers, some 10whp and 18lb-ft.

What are you doing with the Borla's?

[DLC]

I wasn't disappointed with the Borlas so much as I was lured by the price of the TWE headers from a guy parting them out.

There should be extra performance here, which is attractive to anyone not running a turbo, maybe some economy, a different sound and somewhat-uncharted territory for Legacy owners.

I've heard a thing or two about the OBX, but the TWE were the only ones I could get that wouldn't necessitate the replacement of my Random cat, by just replacing the headers as a bolt-in.

There might be a few cracks in the Borlas, where the pipes are braced, but a skilled welder would probably be able to seal them up. I'd like to sell them, if anyone is interested in some later revision Borla headers.

[BAC5.2]

I might be interested.

I wonder how they'll sound with a stock catback though...

[DLC]

I'm sure it'd help, but it's something I'd do with a catback or muffler.

[BAC5.2]

I want less wussy sounding, and greater economy. But not loud. More low end torque is my main goal.

[DLC]

So you're keeping the Forester?

I'm sure it'd help, even with the stock parts, but economy and silence often butt heads, even when there's no turbo involved. I'm actually kinda glad that the car is quieter now than before.

[skid542]

Those look nice. I've been pretty intrigued with the OBX/TWE myself. Have you noticed any difference in power/driveability between the Borla and the TWE? Any particular reason you changed from the Borla to the TWE?

*half hijack* Is the exhaust flange the same between the 2.5 dual port and the 2.2 dual port?

Incase you were wondering, I may be pretty interested in your Borla's if Phil decides he doesn't want them.

[BAC5.2]

The WRX would be $2000+ a year for insurance.

Plus, the allure of my future plans, and lifting the Forester are too great.

[DLC]

skid542:

I wasn't disappointed with the Borlas so much as I was lured by the price of the TWE headers from a guy parting them out.

There should be extra performance here, which is attractive to anyone not running a turbo, maybe some economy, a different sound and somewhat-uncharted territory for Legacy owners.

I've heard a thing or two about the OBX, but the TWE were the only ones I could get that wouldn't necessitate the replacement of my Random cat, by just replacing the headers as a bolt-in.

You're also the fourth person to express interest in them I'll have to check timestamps to make sure though.

I'm going to take more pics of the Borla and try to make sure I know where the cracks are and what the condition is.

As for performance, I need to swap in new plugs and wires before I can truly say anything. It feels good, but the change in sound is distracting enough that it's making the butt dyno not work properly.

Phil: makes sense.

[BAC5.2]

Post a vid so we can compare!

I figure the header alone with a stock catback should give me a bit more breathing capability, without being hellacously noisy. It's all about low-end for off-roading.

[Legacy777]

*half hijack* Is the exhaust flange the same between the 2.5 dual port and the 2.2 dual port?

Yes, they're the same.

[DLC]

I replaced the plugs and wires on the car last night ($$$) and the car is running much better now. I'll have some videos possibly this week, before and after in the garage.

I also want to do another set of driveby videos with the new setup running right.

Have you watched the videos I have on YouTube?

Uphill Acceleration
To 60
Exhaust Samples
Exhaust Samples Two

Here's a closer picture of the cracks on the header. This is from 2005, but they don't seem to have gotten any bigger in the meantime. I'll take more pics, maybe this week (it's a busy one).

[BAC5.2]

Holy shit your brakes are noisy in the third video! I couldn't hear the exhaust.

Those are with the Borla headers, right?

[skid542]

Thanks for the updates and the answers to my questions Dave.

I guess I'll politely take my place in line for the headers, where ever that may be .

[DLC]

BAC5.2: yeah, that's with the Borlas.

One of my rear pads was wearing funny and was scraping, which I just took care of two weeks ago. I didn't know it was making noise till I edited the video!

[DLC]

Here are some closeup photos of the cracks and other welds:























Other than the brace cracks, it's in great shape. You'd need a TIG welder to repair it, of course. I'd recommend removing the brace, filling in the holes and adding another brace, maybe one that wraps around the pipes and doesn't put as much stress on those two welds.

[PhyrraM]

My bro has Borlas on his 2.5RS. Same cracks. They all must do it eventually.

I cut the brace off, regular MIG welded the cracks up. Flux cored wire even. We chose not to reinstall the brace. Been 20K+ miles and the cracks have not re-appeared.

I think the brace "fights" the tubing as the header expands, causing the cracks. So far no ill effects from not having the brace there.

[skid542]

FWIW, even with the cracks, I'm still highly interested. Keep me posted .

[BAC5.2]

JB Weld?