ARCHIVE 100 Series Cat-back Exhaust

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I installed the no cat midpipes myself today, I noticed a couple things while installing them.

  1. Installing the gaskets on either end was a pain in the ass. I have no idea if I got them seated correctly. The last one I tried I used some scotch tape to tap the gasket on, now however after installing everything I can hear the tape fluttering inside the tube. I expect it will burn off with a decent drive, I only took my rig out for 15 mins to make sure nothing was screwed up.
  2. There was no gasket for the front to hook up to the headers. I reused the ones that came out since they looked new from my DT install last year
  3. There was no hardware to hook the O2 sensors up. I had to run to the store to buy some M8 hex bolts with lock washers
  4. There was no gasket for the O2 and the original gaskets crumpled to dust when I took the sensor off. I'm hoping I don't need gaskets because I didn't use any.
  5. I have a bunch of nuts and washers that I have no idea what they go to. Some simple instructions would have been nice.

The process was pretty easy, never having touched exhaust before it wasn't too hard, I'd like to hear any suggestions from anyone else that has installed exhaust before. Especially on how to get the gaskets to stay in the right place while holding up the pipes and trying to start bolts to get it all together.
 
Baktash, what are these washers and nuts and where do they go? In what order? I installed the mid pipes Friday and kinked a gasket so I'm fixing it now and don't want to leave anything out.

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00N8 said:
Baktash, what are these washers and nuts and where do they go? In what order? I installed the mid pipes Friday and kinked a gasket so I'm fixing it now and don't want to leave anything out.

View attachment 718999
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That is a set of 6 locking nuts that we use on the studs that the come off of the headers and attach to the midpipes. They work much better than the factory locking nuts and stay in place for a lifetime.

Three studs at the end of each manifold like in this photo:

IMG_2653.jpg



This diagram shows how you install them:

fordheader.jpg


A couple of videos of how they work:
http://www.youtube.com/watch?v=a3lJqdtTY6A
and
http://www.youtube.com/watch?v=U15OxrX_NBc
 
petrotk40 said:
cool idea. Do those rattle?
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Not at all, they stay on there very firmly and are a mechanical locking mechanism. They work much better than the friction locking nuts that are used from the factory. We use them on everything we can.
 
That helps. Since I have the DT headers there are no studs on my headers only free floating/removable bolts and they don't fit the nuts you provided so I ended up using them on the back part of the midpipes to hook up to the cat back. I'll try to find some nuts and bolts like these above later and replace all the hardware I have between the headers and midpipes.
 
00N8 said:
That helps. Since I have the DT headers there are no studs on my headers only free floating/removable bolts and they don't fit the nuts you provided so I ended up using them on the back part of the midpipes to hook up to the cat back. I'll try to find some nuts and bolts like these above later and replace all the hardware I have between the headers and midpipes.
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I'm not sure what thread size the DT hardware is. At the header we use the same thread as Toyota for our hardware 10x1.25
 
baktasht said:
I'm not sure what thread size the DT hardware is. At the header we use the same thread as Toyota for our hardware 10x1.25
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I'm not sure either. Someone else installed it and there are 14mm and 16mm nuts so likely it was whatever bolt someone could find.



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This is what I did on the back. I had to adjust both front and bak twice to keep leaks from occurring but the clamps to the magnaflow let in air when testing with a flame. Is that usual?

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scottm said:
My muffler is going on my stock exhaust, what is the lead time for a cat-back system?
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Each one of these systems is hand fabricated at our facility here in Austin, Texas. Depending on when you order and what our build queue load is like, lead time is around 5-10 business days from the time you order until it ships out. If you ordered today it would be approximately 6 days.
 
Several more 100-series exhaust systems heading out the door today. This one is heading to Colorado, quick photo before being boxed up for shipping.

Get your orders in soon. The introductory pricing ends on January 31st.

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I placed my order today, but the intro pricing for the midpipe had already changed. I assume I can still get the lower price correct? Feel free to PM me and I'll give you my name/email. thanks
 
mgoblue said:
I placed my order today, but the intro pricing for the midpipe had already changed. I assume I can still get the lower price correct? Feel free to PM me and I'll give you my name/email. thanks
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It was an error on our end on the website. It's all fixed now and the intro pricing is available through end of day tomorrow night. Let me know if you have any questions. We're also available by phone 512-686-2800 or sales@emspowered.com
 
Just ordered a cat-back setup less than an hour before the promo pricing expired. Went right down the wire to convince "Management" to pull the trigger.
 
Have spent a week or two driving with my full exhaust swapped over and couldn't be happier.

Great upgrade. Straight forward install. Power increase and the truck feels smoother in acceleration.
Not that 6850lbs accelerates fast.

Here is the kit that was ordered. Came with all mounting hardware needed. There were a few duplicate gaskets sent. One thing that you should get ahead of time is new oxygen sensor gaskets. One of mine did not come off in one piece. They are inexpensive so save yourself the Sunday afternoon parts store shuffle and just get them before hand.


Soak your header to midpipe bolts ahead of time. Mine weren't that bad. I re-tapped the threads just to make sure. Took a CrudThug to where the old gaskets were to clean them up.

When installing the parts they will appear to hit things as you put them together. They will move into place once tightened. Guide them in position before locking them in. I installed everything loose and then started from the front and torqued everything down.

I had to 'massage' the holes slightly for the oxygen sensor studs. Not sure if it was the new gasket on the one side but a little die grinder to the opening and they studs slipped right in. I could have tried pushing harder but I didn't want to ruin the threads so a quick buzz with the die grinder and they went in. You may or may not have this issue.

This is where sourcing new sensor gaskets will save you some panic time when only one of them comes off.

Everything else just tightens up. For installation I removed the sensors and put them in after. They stick up high when trying to move the pipes into place. I didn't want to damage them so I put them in after and clipped in the wiring.

I have an ARB rear and the rear exhaust will hit the bumper. This is easily remedied by prying on the exhaust hanger on the exhaust and tweaking the exhaust tip downwards to gain the clearance.

The sound isn't as loud as I thought it would be. This is good. I like to not draw attention coming home late at night. I knew it wasn't going to be factory Lexus quiet. I also didn't want Cherry Bomb loud. It's quiet at idle and under acceleration it gives off the 'Yes I'm a V8 sound' which is not overbearing. Just enough to know that you've modified the exhaust. The seat of the pants dyno feels an increase in power. It looks great as well.


Thanks to Shane (AATLAS1X) at Metric TLC -LabRak for allowing me to have it shipped to his shop to save on shipping costs. I'll have a write up of my trek to have the LX470 leather seats installed. They also look great and couldn't be happier with the seats and install. But that will be another thread.





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JDMGoodness said:
Have spent a week or two driving with my full exhaust swapped over and couldn't be happier.

Great upgrade. Straight forward install. Power increase and the truck feels smoother in acceleration.
Not that 6850lbs accelerates fast.
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The weight on my Truck is 5200. What makes yours weigh so much more?

Thanx for the great pix and write up!
 
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