2006-2007 SAI Header block off plates for Thorley Headers (1 Viewer)

[Zuberg]

After reading of multiple issues with the Thorley SAI headers for the 06-07, I'm looking at other install options.

Currently waiting on a quote for stainless steel (304) block off flanges/plates that would allow installation of the earlier 98-05 Thorley headers on 06-07 trucks. With SAI equipped trucks, you either need to block off the SAI head ports with a plate or tap the holes and block off with nutserts and hi temp threadlocker. Obviously plates are less permanent.

The way this works is: install 06/07 OEM gasket, then stack block off plate (1/8 or 3/16"), then thorley gasket, then header and bolt down.

Pros:
-98-05 Thorley headers are significantly cheaper and seem more readily available
-No concerns with primary tubes rubbing on frame/mount like the 06/07 SAI headers
-easier installation - no blind bolts w/ the SAI tubing

Cons:
-for 'off road' use only
-have to disable/bypass the SAI system (Hewitt kit for $100ish)

Probably more pros and cons I'm missing...this is not a new concept. Folks have been doing this on other 2uz vehicles for some time (Tundra, GX, etc).

Anyways - let me know if there's any interest and post up concerns, etc. This would be at most a small batch production and not a regularly stocked item.

Block offs would look something like this (These are 2uz tundra block offs)

 

[Zuberg]

Got pricing on these block off plates.

Pricing is $200/pair in 304 stainless IF we get minimum 3 buyers. This eats into the economics of using 'cheaper' non AIP thorley headers so not sure if the math actually supports going this direction now. I'll crunch numbers later. Most of the cost we'd be paying is setup/table time on the water jet.

If anyone is interested let me know. This would be a one-off batch.

 

[jaewastooshort]

just out of curiosity b/c I've been looking at having parts made this way, have you looked at the cost of having these cut by a company like send cut send? I have no idea how competitive they are on pricing but I'd be curious to know what the difference is if you have those numbers.

 

[Zuberg]

just out of curiosity b/c I've been looking at having parts made this way, have you looked at the cost of having these cut by a company like send cut send? I have no idea how competitive they are on pricing but I'd be curious to know what the difference is if you have those numbers.

I don't have the cut file or I'd certainly get a quote. I even have access to a plasma table but my free time is scarce and I don't have much experience putting together cut files.

 

[Zuberg]

Just to put a bow on this - there was no interest so not pursuing it. Cheaper to just tap and plug the SAI ports in the heads.

If anyone decides they want the block off plates, hit up the owner @ dirty deeds. Great communication and nice guy.

Dirty Deeds Industries

Stainless Steel standard Exhaust system for Toyota Truck or SUV

dirtydeedsindustries.com

 

[zgfiredude]

I missed this originally, sorry for that, however I tend to agree with your conclusion ultimately. Thanks for the effort!!

 

[J1000]

After reading of multiple issues with the Thorley SAI headers for the 06-07, I'm looking at other install options.

Currently waiting on a quote for stainless steel (304) block off flanges/plates that would allow installation of the earlier 98-05 Thorley headers on 06-07 trucks. With SAI equipped trucks, you either need to block off the SAI head ports with a plate or tap the holes and block off with nutserts and hi temp threadlocker. Obviously plates are less permanent.

The way this works is: install 06/07 OEM gasket, then stack block off plate (1/8 or 3/16"), then thorley gasket, then header and bolt down.

Pros:
-98-05 Thorley headers are significantly cheaper and seem more readily available
-No concerns with primary tubes rubbing on frame/mount like the 06/07 SAI headers
-easier installation - no blind bolts w/ the SAI tubing

Cons:
-for 'off road' use only
-have to disable/bypass the SAI system (Hewitt kit for $100ish)

Probably more pros and cons I'm missing...this is not a new concept. Folks have been doing this on other 2uz vehicles for some time (Tundra, GX, etc).

Anyways - let me know if there's any interest and post up concerns, etc. This would be at most a small batch production and not a regularly stocked item.

Block offs would look something like this (These are 2uz tundra block offs)
View attachment 3720057View attachment 3720058

This might save you some bucks: 06/07 Air Induction Pump Failure & Bypass - https://forum.ih8mud.com/threads/06-07-air-induction-pump-failure-bypass.814912/post-14138738

 

[Zuberg]

This might save you some bucks: 06/07 Air Induction Pump Failure & Bypass - https://forum.ih8mud.com/threads/06-07-air-induction-pump-failure-bypass.814912/post-14138738

That's exactly the plan. Bought all the same stuff you used and will do it while I have the motor out for the re-seal. Thanks again for providing those details.