Carbon8 Build
Glad you got it fixed.
01-29-2015, 08:37 PM
#605
In July of last year I was reached out to by Charles (BHR) in regards to his then prototype designed long tube header. After some brief conversations about my car, setup and his views on the market and desired outputs it was agreed upon that I would be given the chance to get my hands on one of his products before it went to market. Ultimately 3 people including myself where chosen to field test a pre-market edition of this header, I have been in direct contact with the other two field testers (who at this time I will not divulge names, but if they feel to comment below that is their choice). So far to my knowledge this is the second header to be fit onto a S1 chassis, the first being the one Charles dyno tested some months back. Ultimately as my schedule shifts wildly depending on m business requirements I was only able to be home for a quick 4 weeks this December and have been avidly working on this since the start of the month.
Black Halo Long Tube Header, whats in the box?
Install
My initial perception of the install was like most headers we have, drop the passenger motor mount remove the old install the new. Unfortunately this was not the case. In order to install the header I had to remove both motor mounts and push the engine to the drive side of the engine bay and it was a very tight fit, I did notice that if you remove the header stud from the bottom of the rear iron exhaust port that it frees up a lot of room on the install. Just be sure you install the stud again and sink it into the iron before you try to bolt the header to thee engine. Depending on individual skill level I would give this header a 2-4 hour install time depending if you have a lift or jackstands
Fitment
The header was originally designed on the chassis of a stock S1, then (and I may be wrong) transferred over to a jig to make the 3 pre-market products. As my car is no where near a stock S1 I did run into 2 installation fitment issues which did require some modifications in order to overcome.
The first fitment issue was the downstream O2 sensor would hit the tail of the S2 trans, as this was never tested with the bigger S2 trans, which has much more reinforced ribbing at the tail then the S1 trans this issue is due to this. A simple 15 degree rotation of the bung location can correct this issue, but as I did not have that option I decided to notch the trans ribbing enough to clear the end of the sensor loom.
Black Halo Long Tube Header, whats in the box?
- BHR Long Tube Header
- BHR Midpipe
- Engine-Header OR Gasket
- Engine-Header Nuts
- Header-Midpipe 2ply gasket
- Header-Midpipe Bolts
- Midpipe-Catback Donut Gasket
- Midpipe-Catback Spring Bolts
Product Review
A quick side by side comparison between my existing header and midpipe (Exoticspeed header and OBX midpipe). The quality of this product is as to be expected from Charles (BHR) with a very well put together piece, clean and welds and top notch materials.
A quick side by side comparison between my existing header and midpipe (Exoticspeed header and OBX midpipe). The quality of this product is as to be expected from Charles (BHR) with a very well put together piece, clean and welds and top notch materials.
My initial perception of the install was like most headers we have, drop the passenger motor mount remove the old install the new. Unfortunately this was not the case. In order to install the header I had to remove both motor mounts and push the engine to the drive side of the engine bay and it was a very tight fit, I did notice that if you remove the header stud from the bottom of the rear iron exhaust port that it frees up a lot of room on the install. Just be sure you install the stud again and sink it into the iron before you try to bolt the header to thee engine. Depending on individual skill level I would give this header a 2-4 hour install time depending if you have a lift or jackstands
Fitment
The header was originally designed on the chassis of a stock S1, then (and I may be wrong) transferred over to a jig to make the 3 pre-market products. As my car is no where near a stock S1 I did run into 2 installation fitment issues which did require some modifications in order to overcome.
The first fitment issue was the downstream O2 sensor would hit the tail of the S2 trans, as this was never tested with the bigger S2 trans, which has much more reinforced ribbing at the tail then the S1 trans this issue is due to this. A simple 15 degree rotation of the bung location can correct this issue, but as I did not have that option I decided to notch the trans ribbing enough to clear the end of the sensor loom.
The second fitment issue was a larger hurdle to get past, and I am not sure how exactly this came to pass if it was due to a previous modification I have made, or something that was lost in translation going from chassis-jig-chassis manufacturing. The rear iron runner after its loop to overcome the motor mount is then routed to the outside of the header, after initial install I noticed this runner came extremely close to the front sub-frame pinch weld rail, and was confirmed when I installed motor mounts again the runner actually rested on the weld and kept a portion of the weight off the motor mount entirely. This was not an easy fix, but their are two options. I could either modify my motor mounts to add an additional 10mm of engine clearance or I could modify my sub-frame. As 10mm was to much out of my comfort zone I decided on the later. Ultimately about 7" of pinch weld were cut out of the sub-frame and I welded the opening together, after I was left with bare metal I laid down 3 coats of 2,000F header paint, and then covered it with 1800F direct contact DEI tunnel II heat shielding. At the beginning I was skeptical but the end result came out very well done and to the caliber or work I have come to expect.
The rest of the install was very smooth, all supplied hardware was top notch to help with the install and it fit up with my catback with no issues while leaving plenty of clearance on all sides for heat dissipation and I was able to take some initial engine warm idle temps, with 956F EGT, the runners say around 650, while the flange is 250. The heat shielding stays relatively cool at 160
Install Review
Initial review of the product installed, is much less raspy then my previous exhaust, but also better flowing system and a slight increase in throttle response as well as rev range. I have dead on AFR compared to my old system and my current map. At this time I am only able to no-load test, and due to my schedule will not be able to get it on a dyno until March, but my inital reaction is impressed with the differance over my prior system.
As far as how it compares in sound it is quieter that my previous straight pipe setup, but much more throaty and responsive as well. An Overall great change (Vid's below).
More will come, load testing as well as direct dyno comparison between my old system. I will update with more as soon as I can. In the mean time feel free to ask for any testing or specifics you would like but keep in mine all technical questions should still be directed at Charles, I can only tell you what they are, not the why.
Install Review
Initial review of the product installed, is much less raspy then my previous exhaust, but also better flowing system and a slight increase in throttle response as well as rev range. I have dead on AFR compared to my old system and my current map. At this time I am only able to no-load test, and due to my schedule will not be able to get it on a dyno until March, but my inital reaction is impressed with the differance over my prior system.
As far as how it compares in sound it is quieter that my previous straight pipe setup, but much more throaty and responsive as well. An Overall great change (Vid's below).
More will come, load testing as well as direct dyno comparison between my old system. I will update with more as soon as I can. In the mean time feel free to ask for any testing or specifics you would like but keep in mine all technical questions should still be directed at Charles, I can only tell you what they are, not the why.
01-29-2015, 09:04 PM
#606
Posting here for internal discussion that I do not want publicized in the official review but a place to put my own observations and discussion points.
Regarding the subframe fitment, I got pictures from the first prototype that was built on a chassis and have confirmed that my pre-market header and the other two released to the testers have a dimensional difference on the rear runner.
Prototype, runners are even in height.
Pre-market, the rear runner is stagger lower than the inner runner.
I have communicated to Charles and he is investigating and I have no doubt will have the issue rectified shortly. Until then we wait for the other two pre-market headers to be installed and confirm this finding.
Regarding the subframe fitment, I got pictures from the first prototype that was built on a chassis and have confirmed that my pre-market header and the other two released to the testers have a dimensional difference on the rear runner.
Prototype, runners are even in height.
Pre-market, the rear runner is stagger lower than the inner runner.
I have communicated to Charles and he is investigating and I have no doubt will have the issue rectified shortly. Until then we wait for the other two pre-market headers to be installed and confirm this finding.
01-29-2015, 09:16 PM
#607
On an unrelated side note, fire extinguisher and bracket are my next priority. It has been in my mind for some time now with all the additions to this car and added wiring etc. that is it ever caught on fire I would never get it back.
I have purchased an H3R Halotron extinguisher with their quick release mount and will be fabrication a passenger seat floor mount.
H3R Performance | HG250B - Halotron Fire Extinguisher - Black
NB300 Quick Release Fire Extinguisher Bracket | H3R Performance
I have purchased an H3R Halotron extinguisher with their quick release mount and will be fabrication a passenger seat floor mount.
H3R Performance | HG250B - Halotron Fire Extinguisher - Black
NB300 Quick Release Fire Extinguisher Bracket | H3R Performance
03-15-2015, 08:32 PM
#610
Couple of recent progressions have come to light, through communication with BC I was arranged a new set of coilovers complete with testing, I also recieved my UAO from last oil change (slacking on that one)
Coilover Dyno Plot Top Front, Bottom Rear(2/10/15)
UOA
Lastly I have received my extinguisher and bracket, will be fabricating a passenger seat mount this weekend
And what everyone has been waiting for, my Dyno is scheduled for 3/19/15, had the car out running around today and the exhaust is much quieter and smoother throughout the rev range, AFR are right on my tune. Will have data and video's to be posted by the weekend.
Coilover Dyno Plot Top Front, Bottom Rear(2/10/15)
UOA
Lastly I have received my extinguisher and bracket, will be fabricating a passenger seat mount this weekend
And what everyone has been waiting for, my Dyno is scheduled for 3/19/15, had the car out running around today and the exhaust is much quieter and smoother throughout the rev range, AFR are right on my tune. Will have data and video's to be posted by the weekend.
03-19-2015, 09:14 PM
#613
Just finished compiling everything from today's session. Firstly some impressions and recap.
I have driven about 200 miles this week with the header install, with not adverse signs. AFR, LTFT, STFT, and everything else is dead on as well my heat shielding is holding up great and the notch for the downstream censor is working perfectly. As far as audio, this exhaust is much quieter than my previous straight pipe system (as expected) no drone, less rasp and all around sounds like a more mature system and have gotten many compliments on it.
As per the power output, a little back story. I am no longer doing my dyno's in 5th as the gear is to tall and deemed both to stressful on the motor and unsafe speeds on a dyno. So I have 4th gear Dyno's to compare. Now my car stock back in 2012 put down 214WHP and 141WTQ in 4th, last year after my rebuild and extensive NA build it managed 221WHP and 148WTQ (this is the Dyno I compare to) not only did my build yield some top end gains but was more impressive was the mid-range yield of about 8% from 3500 and up.
The below dyno is on a Mustang Dyno which made 223WHP and 154WTQ on the top end, and also yielded an additional 5% from 3800 and up. So on a heavily modified NA engine this product still manages to extract a noticeable increase in untapped potential.
My log graph, the AFR dips a little lower than my target (12.2) but nothing to drastic I may jump this up a bit at a later date but this was taken on the same tune I established last year. MAF readings in excess of 260G/sec
Here is the video as well.
I have driven about 200 miles this week with the header install, with not adverse signs. AFR, LTFT, STFT, and everything else is dead on as well my heat shielding is holding up great and the notch for the downstream censor is working perfectly. As far as audio, this exhaust is much quieter than my previous straight pipe system (as expected) no drone, less rasp and all around sounds like a more mature system and have gotten many compliments on it.
As per the power output, a little back story. I am no longer doing my dyno's in 5th as the gear is to tall and deemed both to stressful on the motor and unsafe speeds on a dyno. So I have 4th gear Dyno's to compare. Now my car stock back in 2012 put down 214WHP and 141WTQ in 4th, last year after my rebuild and extensive NA build it managed 221WHP and 148WTQ (this is the Dyno I compare to) not only did my build yield some top end gains but was more impressive was the mid-range yield of about 8% from 3500 and up.
The below dyno is on a Mustang Dyno which made 223WHP and 154WTQ on the top end, and also yielded an additional 5% from 3800 and up. So on a heavily modified NA engine this product still manages to extract a noticeable increase in untapped potential.
My log graph, the AFR dips a little lower than my target (12.2) but nothing to drastic I may jump this up a bit at a later date but this was taken on the same tune I established last year. MAF readings in excess of 260G/sec
Here is the video as well.
Last edited by Carbon8; 03-19-2015 at 09:18 PM.
The following users liked this post:
acbauza (11-26-2023)
03-19-2015, 09:36 PM
#614
On a side note, car has been coming together exceptionally nice lately, everything has been running dead on suspension is all fixed...........you know one of those its going to well things. So my check engine light decided to be a ***** late tonight on my way home for an EVAP code 
Also looks like today marks the 3 year mark and 10,000 miles over ownership since I have purchased this car which is the longest I have ever owned a car, but at the same time I think my Bumper to Bumper expires soon. Might need to trade it in
Also looks like today marks the 3 year mark and 10,000 miles over ownership since I have purchased this car which is the longest I have ever owned a car, but at the same time I think my Bumper to Bumper expires soon. Might need to trade it in
03-20-2015, 08:06 AM
#617
I never expect much, to be honest I feel my Dyno's have always run high I mean 214WHP stock? I am waiting for the day when I go in and struggle to make 180
But I will say everything has been very consistent. I will be venturing out in the area more this summer to get some other Dyno's to compare maybe find a Dynojet.
I am disappointing that I was not able to get a 5th gear pull but it was not a good time last year, any dyno pull over 1 min and temps in excess of 220 is not something I want to do again.
03-22-2015, 06:38 PM
#618
Another small project I have been working on as well is a fire extinguisher solution (surprised someone else hasn't come up with a bracket by now to be honest). I wanted something that was easily accessible and if ever needed would not be a hassle post use. So I picked up one of H3R Performance haltron units in a 2.5lb package, and one of their quick release bracket systems
H3R Performance | HG250B - Halotron Fire Extinguisher - Black
NB300 Quick Release Fire Extinguisher Bracket | H3R Performance
Found the time this weekend to mock up and fabricate a pretty basic passenger seat mount and fit it. Unfortunately with the extinguisher mounted on the bracket the seat will not be able to be adjusted from its utmost back position but a simple pull of the pin and taking off the extinguisher will render the seats normal function again. Figured in the 3 years of ownership I have never had a back seat passenger so "who cares" :dunno". All in all turned out great, and is now sitting waiting to go the PC once I get a couple more pieces I am waiting for.
*If you are interested in such a seat bracket please PM me, if I get enough interest I may be able to do a production run of these (Leave an email address to be contacted at).*
H3R Performance | HG250B - Halotron Fire Extinguisher - Black
NB300 Quick Release Fire Extinguisher Bracket | H3R Performance
Found the time this weekend to mock up and fabricate a pretty basic passenger seat mount and fit it. Unfortunately with the extinguisher mounted on the bracket the seat will not be able to be adjusted from its utmost back position but a simple pull of the pin and taking off the extinguisher will render the seats normal function again. Figured in the 3 years of ownership I have never had a back seat passenger so "who cares" :dunno". All in all turned out great, and is now sitting waiting to go the PC once I get a couple more pieces I am waiting for.
*If you are interested in such a seat bracket please PM me, if I get enough interest I may be able to do a production run of these (Leave an email address to be contacted at).*
03-23-2015, 02:27 PM
#620
I can send you the map if you want to take a look.
05-12-2015, 09:47 PM
#623
The leg work has been done, this 3 year build was started with an end goal. The end goal is now officially started with the recent purchase and acquisition of an FI kit.
Looking forward to another very busy, but hopefully smooth and last big build over the winter
A big thanks to Moon for providing a very detailed and top notch kit.
Looking forward to another very busy, but hopefully smooth and last big build over the winter
A big thanks to Moon for providing a very detailed and top notch kit.
05-13-2015, 03:42 AM
#625
And would you be so kind and post a picture if the timing and split? I have WAY to little knowledge around this(Close to zero actually
), and would really appreciate it.