I'm kind of in the same boat. This winter I'm plopping a 3.4L Whipple on the car and looking for some pretty big numbers. Right now I have 1 5/8 Kooks LT's (well short LT's to be exact), 2.5" X and 2.5" tails and Magnaflow Magnapacks.
I would like to go 3" and have plenty of clearance (A Watts link helps a lot with that). But I don't want to go any bigger with the primary tubes and I certainly don't want longer headers. I like being able to remove things like the transmission without touching the headers. Wrapping another set of headers is not high on my list either. And with my motor lowered in conjunction with the stock K-member (haven't seen a tubular one I would want to go around corners fast with) clearance is already tight.
The plan at the top of the list is to cut the existing ball collector off of the 1 5/8 headers, replace it with a 3" collector of some sort and run off the shelf 3" exhaust.
I was thinking of making an entire oval tube "NASCAR" style system for ground clearance/aerodynamics/oval tubing is cool. But there is a good chance at some point I will spin the car off the road course. If I tear the exhaust up I would like to simply order a replacement, not make custom stuff again.
I'm just not sure what to do. I would be pretty bummed out to go to all the trouble to switch to 3" and find out it was worth 40hp for example. 40hp, probably up top in the rev range to boot, not worth the trouble when you are playing with 800+ IMO.
If I saw a decent before/after test of 2.5-3" that made some gains I would probably take the plunge. But at this point doing it because "it should make more power" is tough to swallow.
Thoughts? Thoughts on putting 3" collectors on the 1 5/8 headers?
I put on 1 7/8's with a 3" collector on my Whipple 2.9 GT500 at 18.5-19psi, picked up a good bit of hp. Mainly due to, sitting around calculating flow, that came out to give me the best gains for my manifold pressure.
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