Has anyone done any comparative header testing? The pricing ranges from 150 to over 1000 a large range to cover. I have GM Fastburn heads, Borla cat back, Magnaflo cat, I am pretty sold on the ZZ4 cam Pete K said he had great luck with it and it seems like enough planning on 1.6 intake and 1.5 exh rockers, First intake to match the heads, no EGR already passed smog without one, and air eliminator to clean up engine bay. I have I hope all the tuning tools with tons of experience tuning race engines on aftermarket systems though none on GM stuff tools or no tools. The heads have to be LT1 style headers according to GM to fit the exhaust ports. At the rate I am going the engine and suspension work will be almost as much as I paid for the car..LOL.. something I should have expected.. If it matters I have already eliminated precats as well. It is a 91 A4 coupe if that matters in any way. I like the look and finish of the hookers and ok with painted, that gets me in the 450 range and about the top of the list as far as money goes mentally unless someone has hard data to prove otherwise. Power wise 425 ft/lb and 400 hp the fantasy with a 350 400 ft/lb and 375 acceptable if that helps as well. I am more interested in 0-80 performance than anything else and hope the parts list is appropriate.

 

i never wanted to put 1.6 rockers with the zz4 cam , bought a 1.6 set but i replaced the cam as well

 

Coatings, workmanship of the header are important, and sometimes you get what you pay for.
I have Doug Rippie 1 3/4 headers for my LT1. Fit is awesome, not one issue and they are coated SS. I dont know what version of SS they are, but being DRM they are quality.
Now, no matter what you buy, or size, you will see a gain throughout the rpm range, and better fuel economy as long as you retune it after you install them.
Stainless Steel is the choice for quality material. Yet coatings can overcome that issue, in regards to longevity.
Everyone has their preference, size(Huge debates on 1 5/8 vs 1 3/4), coating, blah blah.
Buy the best quality fitting header you can afford.

 

I ran a zz4 cam in a 72 Nova I had about 5 years ago. Ported vortec heads and full lengths 1 5/8" headers. The first day I got it going I drove 80 miles one way to the drag strip and ran a 13.26 @106 on 60 series tires and full exhaust, full interior, dish top 87 octane. I'm pretty fond of them myself, but went with a zz3 copy for my vette now. It feels MUCH stronger with the same basic setup, but also a little rougher sounding at idle.

As far as headers, I wouldn't concern myself too much with the brand but more the sizes.

you will probably need a 1 5/8" tube, full length (stay away from the shorties ). Also make sure they are at least 10mm (or 3/8") thick flanges, anything thinner and they will warp and leak over time, or even right away. it's also good to stay away from the flanges that are welded on the head side of the flange.

 

Flange thickness is definitely an important issue, as it helps seal the header gaskets to the heads. Thin flanges warp.
Hooker (Coated), Stainless works, Melrose, TPIS (great fitment and quality) etc come to mind.

 

I was looking at the Hedman Elite 68488 as it has 14 gauge tubes instead of 18 gauge coated and 3/8 flanges and 1 5/8 tubes. I kind of like the ball and socket collector adapters as well, they seem like they would be a bit more forgiving on alignment to the Y pipe. Now the rub they are listed up to a 91. The fastburn heads have a .200 raised exhaust port and need the LT1-LT4 header gasket, Fel-pro 1470 for the raised port. I only found one header so far that lists for 84 to 96 so that I can have the later model exhaust port in the earlier chassis. Hooker 2151 but it is 18 gauge tubing with thinner flanges and 1 3/4. So I am open for ideas I really wanted the heavier gauge tubing and all the other features at the under 400 bucks price level. Has anyone ever tryed slotting the flanges to raise the the header up 0.200??

Interesting info on the cam I think I need something with more lift then. I do find it hard to believe the ramps are all that fast on an old GM cam though and without buying one no good way to plot the lobe profile. What ceterline have others installed the ZZ4 cam?