I finally got my exhaust together after a complete buildup that included a Golen forged 383 shortblock, LE2 Top end and 1 3/4" Melrose ceramic coated headers. Very pleased with the end result.

The OEM cats and resonator were removed from the system.
I used the Melrose intermediate 3" aluminized intermediate pipes and decided to build my H pipe instead of the Melrose X pipe.


The X pipe: I really like the sound of the H pipe over the X pipe so I decided to buid my own. Used a little piece of 3" oval pipe to connect the two main pipes.






And the final element: The previous owner had Flowmaster series 40 mufflers installed, and the combination produced a very annoying drone at around 1800 rpm. I substituted these wit the Corvette Central Magnaflow mufflers with LT1 tips. I must say I am very pleased with the combination. These mufflers made a night and day difference. I still get very little drone at the same engine speed, but nothing that bothers(I am 62), and the sound of the H really puts a smile on my face every time I get on it. The CC mufflers lined up very well and the LT1 tips give the car a stock appearence.


One thing I did do was replace the U clamps provided by CC with these exhaust band clamps wich I like to use in my builds. They provide a good seal without distorting the pipe if future disassemblies are needed.

 

Nice indeed! I like that system

 

Why did you decide on Melrose?
I've narrowed it down to TPiS or Melrose for my LE2 build.

 

Not OP, but I was deciding between TPiS, American Racing Headers, and Melrose for my long tubes. I ruled out ARH because their customer support took 3 weeks to get back to me, and were not able to answer my questions about fitment. TPiS doesn't offer a full-length system, which really turned me away from them - I'll pay a little more and not have to do the fab work if I can avoid it. Which left Melrose. They were very responsive to my questions, let me know specific sizes on the headers so I could get the correct exhaust gasket for my heads, and they offered the best installation instructions of the three. The fit and finish on the headers was amazing, and dressing wires and hoses around them was easy. I did run into issues with spark plug wires resting on the headers, which was fixed by some of Accel's ceramic plug wires - they are awesome.
The only issue I ran into with installation was that the arms leading to my mufflers didn't quite meet up with the Melrose system (the Melrose system is made for stock mufflers). This was fixed by expanding the little elbows that Melrose provided with the kit.
The headers look great and sound great. Plus, it let me get rid of my AIR system and Cats. I'd recommend going for the ceramic coated headers, they have my car in closed loop in about 5-10 minutes, without a heated 02 sensor. And when stopped, it stays in closed loop, which I know is a concern for some people who add headers.

 

Thanks for the insight. I plan on using my stock exhaust which has an x-pipe where the resonator was and have heard it sounds great with headers (I wanted a corsa system, but $1400, so half for headers + fabrication labor). No A.I.R or CATs(I will probably do hi-flow to reduce the gas-smelling exhaust)

TPiS doesn't offer a full-length system
do you mean nothing from the headers to the catback?

I bought AC Delco wires, will these be a problem with the Melrose headers or are there certain cylinders that need ceramic plug wires

TIA

 

I went without cats, and after my new ECM + tuning work, the exhaust smells like when it had cats. It was awful before I tuned it, however.

Yeah, TPiS didn't have an x-pipe or dual system for my 85, which is what I was after. 85's had square flange cats, so would have been on my own for sourcing/fabbing everything from the headers to the mufflers. When I went through the steps of sourcing everything I'd need, I was only saving 200 bucks vs the Melrose system. Seeing as I'd have to cut and weld, I opted to spend 200 more and save a few hours.

As for the wires, it depends on your head design. I have straight plug heads, and there are 2 wires that touch the headers, and one that is crazy close. I bent up heat sheilds out of aluminum to try and protect the ones in contact, but they only lasted ~3k miles. A hundred bucks for the ceramic ones, and I've been good since. One wire was hard to get on since the ceramic boot is so thick. I had to take the plug out, put the wire on, then wrench in the plug with the wire on it. But at least they don't burn!

 

I might be a little late to answer your original question Vette196, but I agree with 100% of what The Blaster posted. Melrose also shipped the day after I ordered. Great service and they answered my questions right away.

Regarding your other concern about the wires:

I concur wit the statement that it will depend on your head design. I also bought AC Delco wires. My heads are angle plugs (94 LT1) ported by Lloyd. I used the OEM wire looms and have absolutely no problems with spark plug wire routing. You can get the replacement plastic wire holders from Ecklers and have a full functional wire loom system. No ceramic wires here. The ceramic coating on the headers does a fantastic job keeping the heat inside the primaries.

 

Looks nice, post up a video if you can!