I am having the same issue, anyone ever get a solution from either manufacture (Melrose/Random)

 

To get the system to fit I worked with Random Technologies (who makes everything from the headers back), and sent them a pattern of what I needed. They couldn’t make the pattern though because the straight section is as short as it can be using their CNC mandrel bender (a distance between arc centers issue). Simply, they couldn't bend another pipe to match my pattern anyway! After much convincing I got them to cut the passenger collector (adapter) pipe in the center of the straight section and flare it. This allowed me to position the passenger adapter just as it needed to be and clamp it.

Another note. I never used the two rearmost pipes (left or right). Instead I connected the adapters that connected to the x-pipe directly to the stock 2.75" pipes where I cut them from the resonator. The way I did it I put everything together with clamps (you'll need an extra 3" clamp with that pass side adapter pipe cut and flared) tightened the whole thing up, then drove it to the muffler shop and had them perimeter weld everything except where the headers meet the adapter pipes.

Using everything stock behind the resonator allowed me to utilize the stock springed hanger from the differential on the existing tabs. And, I didn't use the hanger from the rear of the transmission since exhaust is so much lighter. The whole installation makes the exhaust much tighter to the bottom car compared to the stock exhaust. In fact ,I've never hit the exhaust as I did the stock exhaust (although I have hit the driver side header coming down a speed bump - it'll **** ya off). The only other thing I did was wrap the driver side adapter tube in header wrap because it just seemed to close to the body. That seems to help keep the cabin cooler too; no hot feet!

If you're wondering, the car sounds great with the stock mufflers; I couldn't be happier with the solid, throaty sound!

 

For that price and those fitment issues... I think I'd rather buy the x-pipe and build my own. If you can't get a single piece to fit what is needed, you should bend two and have them welded together.

I was actually thinking of using their system too. But if I'm going to have to fab up or modify parts of the system, I might as well build it myself, and have my friend tig it up.

 

Thanks For the info!!!! i can have the pipe bent a little and that should work (just wanted to be sure it was not something with the header) if not I now have two front pipes and can use them to make one that will work.

 

Great thread with good follow-up information!

Steven

 

I'm beginning to think there are some car-to-car differences that are causing problems. I helped one of my friends some Melrose headers and Random exhaust off of his '87 because he sold the stuff to another friend with an 89. The system fit the 87 great, but things didn't line up the same on the 89. It wasn't off by much, but it was definitely off compared to the 87.

 

TRUE! If I had it to do again I'd only buy the headers, and the X-pipe. and have the rest locally fitted.

CONS:
The adapter pipes are made to be installed around the pan of an automatic transmission; so if you have a manual trans. (as I do), there are a lot of the extra bends.

The system is a bit more complex than I need because I don't use any cats. When cats are not used, extra pipes (cat eliminator pipes) and clamps are inclued with the system. I'd rather they'd extend the existing pipes instead of using the two cat eliminator pipes.

PROS:
I did like the fact that I could get the headers without AIR bungs which is very clean looking under the hood.

 

Melrose didnt make a system for the 88 vert when i went looking. I called and brought them my car, they custom made my exhaust from the headers back. The system includes random tech cats and corsa mufflers. I couldnt be happier. It looks and sounds great. Great people to deal with. I would recomend them to anyone.

 

Well the pipe are going on, had to bend one and then cut two down so the mufflers would align,

Mine is an auto with cats and due to fitment issues I would say get the headers and have the exhaust built, don't buy it with the Random exhaust pipes. More time was spent getting the Exhaust to work than it would have taken to build one.

The Melrose headers are A+ the Random exhaust gets an F

 

Yeah, that's a definate advantage to having the tools needed to fab the exhaust myself.

Did you have any clearance issues with yoru headers? I have TPIS and they rub slightly on the passenger side. I am concidering getting a set without Emissions hook up since I don't need them, and they have been blocked off.
How low do the Melrose hang?

 

Melrose headers don't hang any lower than the TPIS headers.

This is definitely weird what is going on with the Random part of the system. I've put a couple systems on and have not had issues yet obviously others have.

The muffler end of the system is not something that will match up to everyones choice of mufflers. That's the one down side to the intent of the system because of all the different muffler choices out there.

Has anyone tried to loosen the motor mounts and tweak the engine a little? I'm wondering if there are some slight differences that end up being big changes further down the line. Just a thought.

 

The Melrose Headers fit perfect with no clearence issues and do not hang down any lower than the body/frame. We spent several hours adjusting everything in the car trying to avoid bending and cutting the system.

Also, we new some mods would be needed around the mufflers but the pipes delivered ended up one third of the way under the spare tire and not in front of it. The only pipe not altered was the X pipe, cats and the drivers front pipe.

I cannot say for other models but if you have a C4 just stick with the headers, they are worth the money and pass on the Random pipes.

Their Instructions should read....Pipe bending and welding required!

 

Just finished my install yesterday. A Couple issues, nothing serious. A.I.R. tube on Pass. side didn't line up. Was off about an inch. Had to bend it a bit to fit. A couple tight places, I had to remove the Pass. side body heat shield for clearance. Pipe and clamp would never have fit around the header otherwise. I plan on wrapping it in header wrap soon. I don't like how there are no supports for the exhaust except the headers and muffler attachment area. There is one bracket but it doesn't line up to anything. I'm going to tap a hole and build a bracket later if i keep the 2 1/2" pipes. There were the usual minor modifications to brackets and wiring. It was a pain in the A$$ but well worth the end result. The Car sounds like a Vette should now. Resonance is terrible but I can't expect much else with the exhaust ending right under the car. Still need to find mufflers. I may bring it to a muffler shop to fab me up a full 3" system with no mufflers.

Final Grade

Quality
headers- A+
exhaust- B+
Fit
headers- A-
exhaust- C+
Sound
A++

All in all I am very happy I purchased this system.

 

OK GANG HERE's Page 2
Late this summer had the ansa mufflers off and 21/2" eleminators with the SS megaphone tips. Went down to Festus Mo. for a tune on the ECM after putting 30# injectors and a custom TPI that not only cut up but custom runners( the old ones cut in half and welded up to have just two tubes per side. With the mufflers off and the tune it is great at idle can here the cam sounds like NASCAR. Really not too loud until you get on it then all hell breaks loose . When going down the hiway at 70 it is quite and reserved you can here the radio and talk (convert) but just wait until you pound it. Yea might be a little loud but hell I'm old. Going to put a couple more crimps in the pipe to see if it will quite a little more of might make up an insert ( made a couple for the kids Harley ).. One thing that was a real suprise the custom tune has made a BIG CHANGE in mileage (the tuner told to see if better). Look we have had it since new (now34k miles) and have never gotten anymore than 23-26MPG. Now that the top end work, the exhaust change and custom tune the mileage last fall was over 32MPG and running between 32-38 on the highway (believe it or not). Hell!! I still have a hard time to see it get like that and have been hitting the gas more often to keep it topped up (don't want to trust the gauge and still is not that low on fuel). This has to be best $350 bucks I could ever spend and will be running it more this summer and will play with the exhaust a little like I said. I will drop a note as we see how the gas mileage goes. wro87

 

Well, I have been fighting the Melrose (Random) installation thing for the last couple of months.

Last night I finally completed the system. Just for reference I have a ’91 vert. I bought the Melrose smooth flow system without air but with EGR. I am happy to report that the Melrose headers are very nice from both a fit and finish perspective. I would highly recommend the headers to anyone. The Random exhaust system was a joke to install. I had to abandon the first two pipes that connect to the headers and have an exhaust shop bend new ones. I also abandoned the L98 rear hanger system in favor of the LT1 style support system that hangs from the differential case. The LT1 hangers provide support for both sides of exhaust as opposed to just one side like the L98 hanger does. Today the exhaust looks nothing like what Melrose originally shipped me. I still have to work out the cross brace issues as I know there is interference and need to figure out just how much shimming will be required.

In summary, I would buy Melrose headers again, however I would highly recommend that everyone stay clear of pre-fab’d Random smooth flow system. I would also recommend that Melrose disassociate themselves from the Random components as those that don’t understand the difference between the two companies will eventually begin to associate the poor fit to Melrose thus hurting an otherwise highly credible business.

My two cents on the subject.

Chris

 

Grace91-
Unfortunately I feel it has come time for that to happen. From here forward we will be sending customers directly to Random or whoever they see fit for the post header C4 piping. In Random's defense the L98 stuff seems to install w/o a hitch, but we will not be stocking that either.
To those of you developing your own system with our headers please keep us up to date as to fit and progress. We are always open to new ideas.
On a different note - Pypes exhaust is developing some C4 stuff, and will be looking into their product when completed.

 

I used some of their cats, cheap and nice.

 

Looking at your photo the center of the s-pipe on the passenger side
is to long. Can't you take that pipe to a muffer shop, have them cut
it and weld it back together?

 

i have 85 melrose headers xpipe 3"pipes dual hiflow cats and 40 series flowmasters very nice sound

 

Well, I have had my Melrose / Random system for about 20 months, and I finally got around to installing it. I am having this exact same problem. I guess I'll have to cut the RH pipe, remove a small section, and reweld it. Doesn't that sound fun.