Exhaust Headers Research Guide

Performance Headers Guide
A handy guide to performance exhaust header coatings

Performance exhaust headers live under some of the most grueling conditions on your vehicle. They are constantly being seared, scorched and singed by the blistering-hot exhaust fumes chugging out of your cylinders. In order to withstand this punishing environment and to avoid corrosion, performance headers are treated with a number of different coatings. Here's a quick reference to the most common types of finishes:

High Temperature Paint:
One of the most basic performance exhaust header coatings is high temperature paint. It lays down an effective barrier against moisture infiltration that can lead to rust. Plus, it's specially formulated to resist cracking, peeling and flaking. Though not as durable as some of the other coatings, high temperature paint is a cost-effective alternative. It's good for mild street use. Pacesetter specializes in this particular finish.
Nickel-Chrome Plating:
Cars and chrome go together like wrenches and toolboxes—it's just a natural fit. For a dazzling dose of chrome under the hood, the nickel-chrome coating is right up your alley. While chrome adds an eye-catching shine, the nickel works to ward off oxidation. Over time and under heavy-duty loads, the polish will discolor slightly. This coating is recommended for mild street use. Get your chrome exhaust headers from JBA Headers, Doug Thorley Headers or Bassani.
Stainless Steel:
Stainless steel exhaust headers do not have a coating. Instead, their resistance to rust and heat comes from the metal itself. There are two types of stainless steel used in performance headers: 409 and 304. The difference is that 304 has more chromium than 409, so it is stronger and is not as prone to corrosion. Both grades of stainless can bear high temperatures, but each type will lose its luster eventually. Stainless steel performance exhaust headers are ideal for mild and moderate street use, as well as for towing. For stainless steel, check out Dynatech, JBA Headers, DC Sport, Gibson or Borla headers.
Ceramic Coating:
Don't let the name fool you—we're not talking about dainty porcelain vases. For the ultimate in corrosion resistance and thermal protection, ceramic coatings are the way to go. The rugged shell is actually baked onto the performance exhaust headers in a red-hot oven. Once cured, the ceramic coating can hold up against the most brutal heat and block against the most insidious rust. Many manufacturers produce their own unique blends of ceramic coatings with either shiny or matte finishes. This type of coating is ideal for serious street performance, heavy-duty towing, and racing uses. Ceramic coatings are used by most exhaust headers companies, including JBA Headers, Pacesetter, Doug Thorley Headers, DC Sport, Gibson, Bassani and Edelbrock

Installation hints

Some auto accessories are easier to install than others. A wireless radar detector, for example, takes mere minutes to setup, but a lift kit can take a whole weekend. Performance exhaust headers take more time than a radar detector and less than a lift kit to mount. For a seasoned garage rat with the right tools, a sturdy set of floor jacks, and an able-bodied helper, it should only take a couple of hours to bolt performance exhaust headers into place.

Listen hear

Fun Factoids: Ceramics—older than Milton Berle and still relevant

Ceramics have been around since the dawn of human culture, and they still play an important role in our modern society. One of the oldest examples of ceramics is the Venus of Dolni, a clay fertility figurine formed around 30,000 years ago. 20,000 years later, in Japan's Joman period, pottery was invented, and the population boomed from the new technology. In 1881, the US Senate approved $300,000 to construct a new White House with more sanitary ceramic (porcelain) toilets after fears that President Garfield's recuperation from an assassin's bullet was hampered by foul sewer gasses spewing up from wooden commodes and poor plumbing. Back in the early 1980s, Toyota built a ceramic engine that could run at over 6000°F without a cooling system. Today, ceramics are used by nearly every industry, from electrical engineering to dentistry. Even NASA uses a patchwork of ceramic tiles to line the belly of the US Space Shuttle. It's amazing what we can do with dirt these days.

In general, performance exhaust headers are designed to tie right into your stock exhaust system or performance cat-back exhaust. Some minor modifications may be needed for select performance headers, but this is rare. Here are a few suggestions that should make your installation run smoothly:

  • Never work on a hot exhaust system. Allow your vehicle ample time to cool down before you start working to avoid burns.
  • Take a picture of your engine compartment before you start disconnecting things. That way, you can have something to reference if you forget where a wire or hose goes during the reinstall.
  • Be sure to use a torque wrench when tightening the performance exhaust header's bolts. Start with the center bolts and work your way out to the sides for a leak-free fit.
  • Go back and re-torque the header bolts periodically. The vibration of the engine can loosen the bolts and cause leaks, but the occasional turn of the wrench will keep them snug on your motor.