There's a method to the madness.
"These build journal entries are part of a Special Series on the InfinityDesign Long Tube & Equal Length S85 V10 headers.
This journal entry covers the installation of the headers. It was done in collaboration with the guys at InnovAuto who did the installation. Thanks for the tips and tricks guys. "
- Matt
A reminder: the V3 design changes.
The most recent V3 design update was implemented to improve the jig's accuracy and precision in order to make installation easier while retaining the signature sound and highest performing header system on the market.
The V3 also eliminated springs on the merge collectors in favour of a slip-on fit. They are sealed at the collector using high temp silicone to allow heat expansion.
As of June 2022, all V3 headers order are now shipped with bolts and nuts with holes on the primaries and merge collector to secure and seal them together. Using high temp silicone is still required.
The Minimum Requirements for Install.
"If you don't have access to have a lift and will attempt this install.
You're a masochist.
If you don't take the front subframe off and don't have a list.
You should see a shrink.
If you succeed still, a DIY award is what you deserve."
- Matt
Using the method showcased here, we knocked out the header install in less than 6 hours. Sal thinks that's a record.
The guys at InnovAuto are professionals with the V10, yet it was the first time fitting these headers.
There's room to be even faster.
How these are delivered.
You were thinking you'd receive these assembled like a work of a art eh?
Nah.
To optimize on shipping fees, and make installation easier, these headers are delivered in pieces.
Deep dive into installation.
Take the front subframe off.
This is where it starts, and it will make your whole life a lot easier.
My install was performed during a rod bearing service which requires it anyways.
The V10s are packaged tightly and often present many "while you're in there".
While the headers aren't exactly maintenance, matching the bearing service with this install is the move of a financially sound V10 owner.
The irony.
Subframe off really gives you immediate, somewhat easy access to the head studs and bolts as well.
Removing the OEMs.
The OEM headers were an exercise in engineering process visibly optimized for first packaging these giant primary catalytic converters and to optimize performance as a secondary objective.
Although a one piece design, they come out rather easily.
Be mindful of not messing up the 02 sensors, they get expensive.
The heat shields also need to come off as some trimming will be required (no pics, my bad!).
First off: test fit the runners.
There's a method to the madness, this is where the puzzle starts.
First off, first the primaries.
Once they are fitted, start tightening the head bolts on the studs.
Some are easily accessible with power tools. A few will require extensions and hand ratcheting.
This is where you're a complete maso if you're not using a lift.
Follow the stickers.
Each of them are carefully marked with a numbered stickers.
The stickers aligned also matches the merge collector. This will be important once fitting the collectors.
Yes, please remove the stickers once you're done (and are sure you are) unless you like the burnt smell and smoke :)
Test fitting the collectors.
Remember the stickers?
Align them.
Get ready, you'll be fiddling.
This is the stage at which you'll be swearing a few times as you need to loosen up some head bolts to realign the primaries.
The suffering will be worth it.
You got it? You sure?
Take a break. You're not out of the woods yet.
Fitting the merge collectors (for good).
Remember this:
"The V3 also eliminated springs on the merge collectors in favour of a slip-on fit. They are sealed at the collector using high temp silicone to allow heat expansion."
This has a lot of good, and some bad if you don't pay attention.
As of June 2022, all V3 headers order are now shipped with bolts and nuts with holes on the primaries and merge collector to secure and seal them together. Using high temp silicone is still required.
Seal them tight, tighter than you think.
Using hi-temp silicone sealant, aka Gasket Maker, apply a generous, copious amount of it to the inner walls of the merge collector.
Hint: we didn't put in enough.
A good rule of thumb is the silicone should drip out of the collectors by the primaries once you fit them.
We didn't pay careful attention here, and we paid for it in spades a few weeks later.
What happens if you do like we do (well, you can't anymore).
It will leak and sound like this.
How it's fixed:
Here's the good news: the merge collectors are easily accessible without having to remove anything.
We couldn't complete remove them to re-apply sealant.
We chatted with Sal and instead tack welded 2x small stripes of metal to the collectors and primaries to hold them together.
It works.
Just do it right the first time.
Notes on heat shields and things to validate.
The front head shields will need to be slightly trimmed in order to clear the headers.
This must be fitted. The S85 V10 generates massive amounts of heat and is packaged tightly.
You never know what could go wrong, and you don't want to find out.
Other things to watch out for:
-
Fit all the 02 sensors and bungs correctly.
Don't thread them. They are $$$. Plug them in too :) -
Make sure your head bolts are torqued properly.
You don't want to drop the subframe again. -
Check the steering column fitment.
The V3s were specifically designed to clear it. If it doesn't something is wrong in your install. -
Tack weld the flange to the collector outlet to fit with the section 1 exhaust.
This isn't required, but is good practice. Infinity provides the flange.
Admire your work.
Step back and enjoy.
Take another break before fitting the subframe again.
These are absolutely beautiful and stunning to look at.
Truly exotic.
Optional engine start for the laughs :)
Next step: get it tuned and clips.
Salman at InfinityDesign developed a Stage 3 tune specifically optimized for the headers.My body is ready for a mad top end.
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