I have a stock '95 z28 and have a couple basic questions on headers. I understand that they (headers) are considered as part of the basic bolt-on mods that you should do first if you're aiming for the 400+ hp range. My question is, are they really worth the trouble, and if so, how much power should you realistically expect from running them? The "trouble" I'm mentioning is the heat they produce and it seems everybody has opti/plug wire problems after putting them in. I understand that you can route your wires in particular ways, etc., but they just get so hot...is it all really worth it? Are they really a big improvement over the stock manifolds, which I hear are pretty darn good as far as manifolds go. Exhaust-wise I plan on getting a nice cat-back setup, just haven't settled on a particular product yet. If I do go with headers, I'd like an easy to install, proven product that bolts right to the existing system (cat?) without any trouble. Is there such a set out there? Thanks in advance for the help, I know I'm all over the place with this but I figured more info is better than not enough...

 

headers are worth doing and the power you get out of doing them kind of depends on your other modifications. They all are trouble to do because you need to lengthen or use extensions for your O2 sensor leads and you need to somewhat customize your spark plug wires. But thousands of people have done them so its not that awful to do - there are a certain percentage of people who are probably sorry they got into it but mostly, they come out well. Coated headers are a must and that keeps the engine compartment heat down a bit. you can piece together a cat back that will bolt together or clamp together (no welding) with careful choice of parts.

 

I've been running headers of various kinds on my 94 for 12 years, and never burned a plug wire, and never lost the Opti (I did have problems with the Opti with stock manifolds). In fact, in all the time I've been on this and other LT1 forums, I've never heard anyone suggest that header heat ruined their Opti.

As Kevin mentioned, get them cera-metallic (e.g. Jet-Hot, HPC, Airborn) coated to hold down the under hood heat. I would not rate the stock exhaust manifolds as "pretty darn good".... amybe you are confusing the exhaust manifolds with the stock intake manifold.

 

Had to read that all the way through to figure out that was supposed to be maybe, lol... I laughed at my self.