okay few questions i have a set of speed daddy headers that im planning on installing very soon i finally have everything i need i have the band clamps the shorter o2 sensor the high temp rtv sealant and everything tonight i was looking at the headers and i noticed The downpipe is alot longer than our factory one and the catalytic converter connection is different what did you guys do to solve this issue?

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Member #3848
2002 Black Bonneville SE Sold But Not Forgotten
2002 White Bonneville SSEi Project car

No added info, but I just started this same project this morning, so I'm really hoping someone chimes in - preferably with complete and detailed directions, tips, and pictures.

Or is that just too greedy?

no but as you go you could do the photo's and say what you did different

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Member #3848
2002 Black Bonneville SE Sold But Not Forgotten
2002 White Bonneville SSEi Project car

The downpipe will need to be welded to the converter. Also, make sure to get a new flex pipe(ZZP) welded in since the SD one is garbage. Do it now and save yourself the headache down the road. This is also a good time to upgrade/replace your converter, mine had 180K+ on it so I upgraded to the magnaflow.

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2001 Bonneville SSEI (His) - Gen V/3.5 pulley/CAI/SD Headers/ZZP 1.9 Rockers/90# Springs/Magnaflow Converter/HP Tuners/180* T-Stat/Trans-Go Shift Kit/TruCool Transmission Cooler/ F-Body Front Brakes/STS Rear Brakes/Tint/GXP Interior September 2015 COTM

2007 Trailblazer SS (Hers) - PCM4Less tune, E-Fans, SLP PowerFlo Exhaust, Hotchkis Sways, PML Tranny Pan, Powerstop Brakes,
"Big 3", Tint

2004 CTS-V (His) - B&B Exhaust, LS7 clutch, HIDs, LED fogs, Powerstop Brakes, Tint

Thanks for the info!

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Member #3848
2002 Black Bonneville SE Sold But Not Forgotten
2002 White Bonneville SSEi Project car

Sigh. Had just gotten the rear header positioned. Now I'm pulling it back out to put the ZZP flex section on, and replacing the converter as well. I was looking forward to having the car out of the driveway Monday, but with shipping, it'll be another week. On the other hand, if I never have to pull that header again, it's worth it.

Better to do it now though. I was in a pinch when I installed mine and didn't do it. 10k miles later I've got a leak and I believe the walls of the pipe are collapsing in on themselves. I've seen a few post recently showing SD flex pipe doing this. Time to remove it again....

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2001 Bonneville SSEI (His) - Gen V/3.5 pulley/CAI/SD Headers/ZZP 1.9 Rockers/90# Springs/Magnaflow Converter/HP Tuners/180* T-Stat/Trans-Go Shift Kit/TruCool Transmission Cooler/ F-Body Front Brakes/STS Rear Brakes/Tint/GXP Interior September 2015 COTM

2007 Trailblazer SS (Hers) - PCM4Less tune, E-Fans, SLP PowerFlo Exhaust, Hotchkis Sways, PML Tranny Pan, Powerstop Brakes,
"Big 3", Tint

2004 CTS-V (His) - B&B Exhaust, LS7 clutch, HIDs, LED fogs, Powerstop Brakes, Tint

My flex section is the one that comes on the rear header, and it's been about 2 years and 35k miles and it's still good. (But now that I've said it, it's going to leak now with my luck).

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-Ryan
2004 GTO....LS1, LSA supercharged 525whp, 6MT
96 SSEi...September 2010 COTM........GONE
04 GTP comp G.... December 2015 COTM........GONE
2013 Audi Allroad Quattro

I wish this was the case for me. Mine started leaking after 5k or so. I did have some troubles installing the rear manifold and may have boogered up the flex? All I know is I wish I had replaced it before lol.

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2001 Bonneville SSEI (His) - Gen V/3.5 pulley/CAI/SD Headers/ZZP 1.9 Rockers/90# Springs/Magnaflow Converter/HP Tuners/180* T-Stat/Trans-Go Shift Kit/TruCool Transmission Cooler/ F-Body Front Brakes/STS Rear Brakes/Tint/GXP Interior September 2015 COTM

2007 Trailblazer SS (Hers) - PCM4Less tune, E-Fans, SLP PowerFlo Exhaust, Hotchkis Sways, PML Tranny Pan, Powerstop Brakes,
"Big 3", Tint

2004 CTS-V (His) - B&B Exhaust, LS7 clutch, HIDs, LED fogs, Powerstop Brakes, Tint

nice! I have thought about headers because they are soo cheap. I would move the flex before the cat and eliminate that U bend off the headers, don't know why they couldn't make that tighter.

Also looks like the cat is upside down, the heat shield normally goes on the top to keep the heat off the floor of the car but it should be fine that way as well.

S

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Shane "RedZMonte"
2004 Z16 Z06: Virgin
2000 SSEi: Kenwood DDX512, 3.25" MPS, ZZP DP, PLog, Puck Mount, NGK TR7's, DHP Tuned
1995 Monte Z34: T04e "60" turbo, 42.5# injectors, Borla Catback, OBDII swap, DHP Tuned, Much more...

Getting the ZZP flex section welded in has been fun. Nobody in town (admittedly a very small pool, given the size of this town) would touch it. Took it to a larger city (for Montana), where the first guy (who has been welding stainless for 20+years, according to his website) sent me to a different welder, who took one quick look and sent me to a different welder, who first suggested yet another welder, but then mulled it over and decided that while TIG welding would be problematic for technical reasons (all three of the welders pointed out where the braided stainless wires were visible at the edge of the flex, which seemed to be the major issue), he could MIG weld it, which wouldn't be as pretty. Fine, I said. It's under the car. As long as it doesn't leak, I don't care if it's ugly.

I pick it up Monday, which means another week sitting on ramps and stands in the driveway. At this point, I'm just glad someone is willing to do it, except for the nagging worry that something is going to go wrong...

Professional welders are really really picky about doing this kind of thing, if they think they can't make it look sexy with a TIG, they won't want to TIG it for you. If you were closer to MI, I'd be willing to TIG it for you, but sorry that doesn't really help you now.

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Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

lol some places are just crazy about what they wont do. I have a couple shops locally to me that would have no problem MIG welding and calling it a day. Its just like any other exhaust part....

S

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Shane "RedZMonte"
2004 Z16 Z06: Virgin
2000 SSEi: Kenwood DDX512, 3.25" MPS, ZZP DP, PLog, Puck Mount, NGK TR7's, DHP Tuned
1995 Monte Z34: T04e "60" turbo, 42.5# injectors, Borla Catback, OBDII swap, DHP Tuned, Much more...

Yeah, the welder called this morning - it's done. Must have been a terrible struggle, all right.