FJ40 Mark/Downey Header (1 Viewer)

[wngrog]

Alright agreed, I am sold!

How do I contact and find the Wizard to weld up a nice connection to the rest of the exhaust or heck, just rebuild the whole thing header to exit?

They sell a great y pipe for an FJ60 but it won’t work on a 40. SOR sells a nice set with a Y pipe that fits on a 40 nicely

 

[Hugh Heifer]

Alright agreed, I am sold!

How do I contact and find the Wizard to weld up a nice connection to the rest of the exhaust or heck, just rebuild the whole thing header to exit?

Any custom exhaust shop should be able to do this for you. A few years ago I got one done locally for $280. I am sure that price is way up now.

 

[PabloCruise]

Could you make a run of the original design while this new design is fine tuned?

I appreciate your enthusiasm, and all y'alls patience...

Brian, it costs thousands of dollars to make a jig; you only want to make ONE. IIRC, it cost Jim $8000 for the jig I inherited 20 years ago.

This ^^^.
As much as we wanted to simply make a copy of the Downey/Mark's header, we just could not leave well enough alone.
@gonzopancho says it best here in this post - there were opportunities to improve the fit.

FJ40 Mark/Downey Header

I would like one as well. Please add me to the list. Thank you very much.

forum.ih8mud.com

 

[PabloCruise]

We are getting close!

Our manufacturer mocked up this latest version on a 40 (film at 11), and then sent it to our industrial designer for review. Our guy is very good. He used to work at BMW NA. He fit the tacked up v3 prototype, made a few notes, and sent it back.

What I will say is that the final product will fit very well, and is a beautiful piece...

 

[CruisinGA]

Mark, in real world use is there a benefit to this header vs. say using 3fe manifolds ?
Whats the cost range looking like for these new headers ?

I put 3FE headers on my 1.5F. I still put in for one of these new headers.
1) 3FE exh flange is thicker than intake so still needed to make "half moon washers"
2) Manifold contacts throttle linkage so I had to bend the part that passes through firewall
3) Cowl drain hose is a very tight squeeze and needs to be silicone (cityracer) or will get smoked
4) the 3FE downpipes are smaller and more restrictive than this header (does it make a difference to an old 1.5F , and the donut gasket seal to the manifold has needed some attention over the 13 years I have used the 3FE header.

 

[Butchk]

Should ambient air find its way into the exhaust stream, the amount of oxygen present in the sensor's active environment is artificially increased.

If this occurs, the sensor will essentially signal a lean condition that isn’t occurring, and the ECU will add fuel, causing a rich condition.

I don’t know that the excess air will ruin an O2 sensor. (The introduction of water certainly will, and excess fuel will.) (edited)

What definitely will occur is that a “self-learning” EFI system will corrupt its own fuel maps trying to compensate for the “lean” condition.

The other thing that could happen: some techs or shade tree mechanics will try to salvage a leaking flange gasket with sealer of some kind.

Doing this risks having the sealer ooze in-ward, contaminating or clogging, and thus ruining the sensor.

I’ve never been able to seal off my Manafre headers ball and socket. The suck air. I can’t tune my EFI Sniper because of that. I have had individuals muffler shops and myself. And suggestions?

 

[Butchk]

I know it’s been a year, but we want this right.

The stainless (new) header is very, very close to the end of production / final design from Mark’s / Downey.

It will fit fine on a 40-series or 55 that has PS box moved "up-front": 60/80 box, Scout, Astro-van, Saginaw, ...

There is a small issue with the factory box, PS or not. Same concern with the conversion on @bottombracket’s fj40 (“Barney”), which runs a mini truck box on Georg’s bracket.

So we’ll tuck the #6 primary a bit more in production. You can see where the heat shield for the mini truck PS box and the header just touch. (The intake is not on the truck for a clearer photo.)

Georg (@orangefj45) has the second prototype and we’re currently waiting to hear from him before pushing the “Start” button.

View attachment 3261246

I’m interested in a setup for a 1978 fj40 running the Holley Sniper

 

[gonzopancho]

Looking for someone with a 2F in a fj55 to test fit. DM please

 

[Butchk]

I want one for my 1978 fj40
Butchk@gmail.com

 

[Pighead]

Looking for someone with a 2F in a fj55 to test fit. DM please

DM sent

 

[PabloCruise]

I want one for my 1978 fj40
Butchk@gmail.com

I will get you added to the list!!!

 

[greenbeast]

I will get you added to the list!!!

Shouldn’t have jumped 12 pages, there’s a list??

I’d be game for couple, one for 2f into PIg and the 77 40.

 

[PabloCruise]

Shouldn’t have jumped 12 pages, there’s a list??

I’d be game for couple, one for 2f into PIg and the 77 40.

Heck yeah Jon!
I think I already have you added, but it might be for just one.
Let me check...

 

[PabloCruise]

Shouldn’t have jumped 12 pages, there’s a list??

I’d be game for couple, one for 2f into PIg and the 77 40.

Thanks! I got you updated to QTY 2.

 

[Camotubebender]

Can you change mine to 2 also?
Thank you

 

[Dianna]

desmocruiser​

Or just wait a little bit longer and you might just see an entire exhaust system available

 

[derail]

I'd be in for one also. Please add me to the list.

 

[PabloCruise]

Can you change mine to 2 also?
Thank you

I most certainly can!

 

[PabloCruise]

I'd be in for one also. Please add me to the list.

I got you added!

 

[PabloCruise]

desmocruiser​

Or just wait a little bit longer and you might just see an entire exhaust system available

Fun stuff!