Corvette: 1996 LT4 (all stock as of now)

I'm looking for full new exhaust for my '96 LT4, and I've narrowed it down to the Melrose C4 Smooth flow exhaust package. Is there anybody that uses this system that could give me some insight? How do you like it? Any resonance issues? How was the installation? Did it bolt right up with no hassles (bending, cutting, usual installation woes)? Also, what did you use for the mufflers (which is the variable of the whole system)? I'm thinking about muffler eliminators for the added sound.

http://www.melroseheaders.com/produc...ystems/c-4.php

Any insight on this product would be great.

Thanks

 

I'll give ya a bump. I'd like to hear how the Melrose system is.

 

Bought the Melrose system last year noEGR,no AIR, No Cats.
87' roadster. They where great on the phone and shipping real quick. The headers bolted in wiht no problems but did have some fit issue withthe extension on the dr's side (automatic) x-brace, called them on the phone and ended up with a conferance call for about an hour tried their suggestion for remedy and it made the pipe not fit at all. Called them the next available day and they sent new pipes FED-ex had them by 10:30 next day . Ended up shimming the x-brace and put a slight bend in it on the drivers side and it bolt up with no problem then, might have lost about 1" of ground clearance (car sits low to begin with the wide rims). The rest of the system was quick and easy had to cut some off the cat elminators (too long). Went with some Ansa Mufflers first and they give me a resonace around 1200-1600RPM other wise quite. Had the exhaust guy order some SStips and made up some eliminators with a couple of crimps in them (chamber) and made sure they came out far enough behind the rear. He had a big grin along with me and the kid(17) nothing sounds better that a SBC with a good exhaust (and cam) . Can't really tell if all the resonance is gone the weather has turn real crappy here and have it put up for the winter. Will be putting it on a dyno later with and with out the mufflers /elimantors, going to do an intake/injector change and ECM tune.
But the guys at MELROSE where good guys to deal with straight-up
WRO87

PS went with JETHOT coating it really drop the temps under the hood and Stage 8 Bolts kinda PITA but work well no retourqe yet.

 

I have the system on my 96 LT4. You will need to get 2 o2 sims to install where the rear sensors went. For mufflers I went with a L98 corsa cat back just to get the mufflers and back pipes. Cheapest way to get the mufflers. I then mounted the mufflers and marked where the pipes out of the cats needed cut and used the pipes from the L98 kit to hook up. It was rather expensive to to buy the Corsas, but my vert has Borlas and the drone drives me crazy on long trips.

 

I'm in the midst of installing Melrose headers, and exhaust including the x-pipe on my 1994 LT1. I've only got the headers on at this point, but everything is going well. I'm taking my time because I'm also doing the rear end and rear bushings so everything is apart now. I got mine without cats and without air pipes so I'm also blocking off the EGR and AIR ports with plates on the intake. I've heard the '94 doesn't require the "downstream" O2 sensor, but they included an two O2 extensions anyway.

The fit and finish of the headers is very good. The headers could have been sanded a little better before being sent off for coating, but the look perfect once installed. The stainless pipes are polished well, not a mirror, but very nice all the same.

I had to grind down the edge of the the alternator bracket that attaches to the header bolt on the left side; and I had to do the same for the dipstick bracket that attaches to the header bolt on the right side.

All and all the install is going well, but I am taking my time and trying to enjoy it. I'm just hoping my ECM can cope with the lack of EGR!

 

The o2 extensions may be for the front o2 sensors, and you'll get an SES light unless the EGR is eliminated from your tune.

 

Not to hijack your thread but I can't seem to find pricing on there website. Do you have to contact them for pricing ?

 

I had heard (or read) the 94 really monitor the downstream O2 sensor. Can you confirm from your own experience that it will set the SES light?

I'm not experienced with the tuning of the ECM (although I'm sure I'll get a chance soon). I'm curious about what it takes to "shut off" the EGR circuit because I've removed all EGR plumbing and valve and installed block off plates with the install of the headers. In addition I'll have to change the speedo ratio anyway because of the 3.73 rear end I just put in. Any suggestions regarding the ECM programming would be helpful.

 

I think they used to have pricing on the site. Its probably better to talk to them anyway, especially regarding the details. I can tell you they knocked off some of the cost on mine for not having the air buretts or the cats.

 

Yeah, don't worry about the post-cat o2 sensor, it won't throw a code.

The EGR codes can be shut off and the speedo recalibrated with TunerCat software.

You can purchase the Tunercat software for ~$100, and an AKM ALDL interface cable for about the same price.

 

I just read your other thread. Maybe you won't have a problem with the EGR delete. When I installed long tube headers and high flow cats, at highway cruise my car kept throwing an EGR code. I just assumed removing the EGR would throw the same code.

 

Thanks, I'll press on with that in mind.

BTW, I'm having the block off plates for both of the ports on the intake made out of T-304, 1/4" stainless plate, and thought I might ask on volume pricing while I'm at it. I'm emailing the CAD files out for pricing next week, and in my experience usually it's worth the setup fee to get more that one of anything made.

I'm just wondering if anyone already makes them, becasue the EGR valve looks a lot like the EGR valve that was on my '91 Saturn and '86 Cavalier. And the other cover is a simple two bolt port cover that could be used in any number of applications.

 

http://cgi.ebay.com/ebaymotors/LT1-L...QQcmdZViewItem

 

Thanks. I wish they had a picture, but I'm sure it's right considering the description. I'm still going to send out the CAD files for a bid since I went to the trouble of modeling them anyway. Maybe it'll be worth it to have them made, if not, I guess I'll buy it from 1234Store on eBay.

 

DOn't go to alot of trouble for something so simple. My son took a piece of aluminum plate (old stop sign) traced the pattern and cut it out on the band saw in no time,then punched the two bolt holes(took a whole 10 min.) You could polishe it up real nice or we bolted it on the intake when before we powder coated the intake came out nice and you really can't even tell it is there.wro87

 

I have thier complete system on my 87 coupe and my dad just put one on his 88 vert. On my coupe it was not a bad job at all. My only complaints are there is no way to use the factory mounting location for the rear support. One was fabbed to work there and there is no way in hell this system bolts up to factory style mufflers like they claim. I have muffler eliminators on my car and I had to have a shop install them from the Melrose system due to they had to bend pipe to make them fit. I don't have any real reasonce to speak of, it's less than my Dodge Ram with Flowmasters.
On Dad's car we had no issues whatsoever with the X-brace. His only issue was again it no bolting up to factory mufflers.
The only other comment I'll make on this is after a phone call or two it was painfully obvious that these guys can offer no real help on the install as I was told "I have never messed with the C-4 stuff so I have no idea, sorry."

As for the system I love it and am very happy to have it.

 

What do you mean, "get 2 o2 sims to install where the rear sensors went"? What do you mean, sims? Doesn't the Melrose system already have a place to put the stock o2 sensors?

Also, I was lead to believe that this Melrose system I linked comes with EVERYTHING besides the mufflers. Why did you need a whole catback system to finish it off?

I looked up under the '96 and took a glance at the stock exhaust. Looks like it's going to be a tough job to get the exhaust out of there. Those exhaust manifold bolts are pretty well hidden (especially on the driver's side). Looks like it'll be near impossible to get a wrench on those bolts. Any feedback about the actual installation process??

 

I also have a stock LT4 considering Melrose, am interested in this post....

 

I can't comment on the entire system, but I have the headers on my car now, and the extender pipes on the way. The headers are amazing quality and fit.

 

Update on my exhaust install from back in February. What started as enjoying the thrill of installation has come to a standstill on the exhaust.

FYI Random Technologies makes the exhaust from the Melrose headers back and that is where I'm stuck with my car. I'm not trying to bash either Melrose or Random because they've both been real good about working to solve this fitment issue. What I'd like to know is if anyone else has run into an issue fitting the adapter pipes (the ones between the header and x-pipe) on the Melrose/Random Tech combination on an LT1 vette. My passenger side adapter pipe exits too close to center by about 35 -38 mm (1.25-1.3 inches). They say they've never had a problem before. This is not a body interference issue, this is purely an issue of getting the two pipes to meet at the x-pipe. Anyone have any experience with this?