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MANIFOLD INFORMATION:
Manifold or header
Aftermarket exhaust manifold
In most production engines, the manifold is an assembly designed to collect the
exhaust gas from two or more cylinders into one pipe. Manifolds are often made
of cast iron in stock production cars, and may have material-saving design
features such as to use the least metal, to occupy the least space necessary, or
have the lowest production cost. These design restrictions often result in a
design that is cost effective but that does not do the most efficient job of
venting the gases from the engine. Inefficiencies generally occur due to the
nature of the combustion engine and its cylinders. Since cylinders fire at
different times, exhaust leaves them at different times, and pressure waves from
gas emerging from one cylinder might not be completely vacated through the
exhaust system when another comes. This creates a back pressure and restriction
in the engine's exhaust system that can restrict the engine's true performance
possibilities.
A header (sometimes called extractor in Australia) is a manifold specifically
designed for performance. During design, engineers create a manifold without
regard to weight or cost but instead for optimal flow of the exhaust gases. This
design results in a header that is more efficient at scavenging the exhaust from
the cylinders. Headers are generally circular steel tubing with bends and folds
calculated to make the paths from each cylinder's exhaust port to the common
outlet all equal length, and joined at narrow angles to encourage pressure waves
to flow through the outlet, and not back towards other cylinders. In a set of
tuned headers the pipe lengths are carefully calculated to enhance exhaust flow
in a particular engine revolutions per minute range.
Headers are generally made by aftermarket automotive companies, but sometimes
can be bought from the high-performance parts department at car dealerships.
Generally, most car performance enthusiasts buy aftermarket headers made by
companies solely focused on producing reliable, cost-effective well-designed
headers specifically for their car. Headers can also be custom designed by a
custom shop. Due to the advanced materials that some aftermarket headers are
made of, this can be expensive. Luckily, an exhaust system can be custom built
for any car, and generally is not specific to the car's motor or design except
for needing to properly connect solidly to the engine. This is usually
accomplished by correct sizing in the design stage, and selecting a proper
gasket type and size for the engine.
[edit] Header-back
Header-back (or header back) is to the part of the exhaust system from the
outlet of the header to the final vent to open air — everything from the header
back. Header-back systems are generally produced as aftermarket performance
systems for cars without turbochargers.
[edit] Turbo-back
Turbo-back (or turbo back) is to the part of the exhaust system from the outlet
of a turbocharger to the final vent to open air. Turbo-back systems are
generally produced as aftermarket performance systems for cars with
turbochargers. Some turbo-back (and header-back) systems replace stock catalytic
converters with others having less flow restriction.
[edit] Screamer pipe
To regulate the boost pressure on turbo charged cars, a custom wastegate is
fitted to allow exhaust gases to bypass the turbine and pass straight down the
exhaust down pipe. This can cause turbulent airflow around the turbine so to
overcome this problem gases can be re-routed down a separate pipe about thirty
centimetres long and vented straight to atmosphere. The reason for the term
screamer pipe is the phenomenally loud jet engine noise they produce which is
popular and highly desirable for car modifiers. Due to the noise and the fact
they miss out the catalytic converter these are not technically for street use.
[edit] With or without catalytic converter
Some systems (including in former time all systems) (sometimes nowadays called
catless) eliminate the catalytic converter. This is illegal in some places if
the vehicle is driven on public roads.
[edit] Cat-back
Cat-back (also cat back and catback) refers to the portion of the exhaust system
from the outlet of the catalytic converter to the final vent to open air. This
generally includes the pipe from the converter to the muffler, the muffler, and
the final length of pipe to open air.
Cat-back exhaust systems generally use larger diameter pipe than the stock
system. Good systems will have mandrel-bent turns that allow the exhaust gas to
exit with as little back pressure as possible. The mufflers included in these
kits are often glass packs, again to reduce back pressure. If the system is
engineered more for show than functionality, it may be tuned to enhance the
lower sounds that are lacking from high-RPM low-displacement engines.
[edit] Tailpipe and tip
With trucks, sometimes the silencer is crossways under the front of the cab and
its tailpipe blows sideways to the offside (right side if driving on the left,
left side if driving on the right). The side of a passenger car on which the
exhaust exits beneath the rear bumper usually indicates the market for which the
vehicle was designed, i.e. Japanese (and some older British) vehicles have
exhausts on the right so they are furthest from the curb in countries which
drive on the left, while European vehicles have exhausts on the left. The petrol
filler flap is normally on the opposite side to the exhaust tailpipe for reasons
of packaging (keeping the filler pipe away from the hot exhaust) but also to
position it closest to the curb.
The end of the final length of exhaust pipe where it vents to open air,
generally the only visible part, often ends with just a straight or angled cut,
but may include a fancy tip. The tip is usually chromed, and is often of larger
pipe than the rest of the exhaust system. This produces a final reduction in
pressure, as well as prevents rusting of the tips, and can be used to enhance
the appearance of the car, like the one in the picture. These are the least
expensive parts of the system.
In the late 1950s in the United States manufacturers had a fashion in car
styling to form the rear bumper with a hole at each end through which the
exhaust would pass. Two outlets symbolized V-8 power, and only the most
expensive cars (Cadillac, Lincoln, Imperial, Packard) were fitted with this
design. One justification for this was that luxury cars in those days had such a
long rear overhang that the exhaust pipe scraped the ground when the car
traversed ramps. The fashion disappeared after customers noted that the rear end
of the car, being a low-pressure area, collected soot from the exhaust and its
acidic content ate into the chrome-plated rear bumper.
When a bus, truck or tractor or excavator has a vertical exhaust pipe (called
stacks or pipes behind the cab), sometimes the end is curved, or has a hinged
cover flap which the gas flow blows out of the way, to try to prevent foreign
objects (including droppings from a bird perching on the exhaust pipe when the
vehicle is not being used) getting inside the exhaust pipe.
In some trucks, when the silencer is front-to-back under the chassis, the end of
the tailpipe turns 90° and blows downwards. That protects anyone near a
stationary truck from getting a direct blast of the exhaust gas, but often
raises dust when the truck is driving on a dry dusty unmade surface such as on a
building site.
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