Open header looks with all...
Open header looks with all the benefits of a mellow exhaust note-could a hot rodder ask for more? I don't think so! Car Chemistry's insert kits are a great alternative to a full exhaust system in many cases.
Building a hot rod is, for the most part, a heck of a lot of fun. Their assembly and the fabrication and installation of their countless components being almost therapeutic-sort of insulating us from the day-to-day drudgery we face in our quest to make a regular living.
Unfortunately, the diminutive size of most pre-'40s vehicles makes planning a build an important aspect, especially when working on vehicles like As and Ts. For those of us who sometimes don't plan out a build as thoroughly as we should (a frequent shortfall of mine, by the way), building the aforementioned models is sometimes like stuffing 10 pounds of parts into a 5-pound bag-there's sometimes just too little space to fit it all in a cohesive manner. One near final portion of those components we try and fit between those narrow framerails is an exhaust system. We usually do get 'em in there and under there, but many times we have to reconfigure the initial placement of some parts and oftentimes live with the added heat-related problems created by stuffing those pipes and mufflers in such close proximity to floors, master cylinders, and fuel/trans cooler lines.
The Car Chemistry Insert Kit...
The Car Chemistry Insert Kit looks really simple but it's the result of a ton of R&D and dyno testing-they not only quiet down the exhaust note but do so without compromising performance. (Car Chemistry actually specializes in muffling systems for race cars and motorcycles where their technology not only cuts noise levels but enhances performance as well.) Though, in my case, and perhaps most cases, powering a 1,500-pound or so hot rod to exhilarating velocities is usually not a problem-the problem is lookin' cool while doin' it.
In the past, I'd spent precious garage time scratching my head and trying to figure out how I was going to go about fashioning an exhaust system (or even running a full system at all) on a couple of traditional-style projects I'd been constructing. Fortunately, I came across a neat line of products manufactured by Car Chemistry. The company manufactures a good-sized selection of muffler/baffle kits designed for use in lakes-style headers (or even exhaust pipes for those who wish to run a full-length system less the bulky mufflers). This product line allows builders a perfect alternative to stuffing a full system under a small hot rod.
My first experience with Car Chemistry baffles were in a flathead-powered A roadster I was throwing together. The roadster was equipped with a set of Speedway Motors lakes-style headers and had very little room for a full undercar exhaust system to connect them to. That's when I saw my first Car Chemistry ad-liked what I saw and placed an order. A few days later my package arrived and when I had the product in hand I was actually more impressed than I thought I'd be-it's a well-made, easy-to-assemble system that I think will be a great alternative to a full system. Plus, I love the idea of my exhaust blasting out of the megaphones at the cowl while still being able to carry on a conversation with a passenger.
Assembling the Car Chemistry inserts kit was a snap and took less than two hours from start to finish. And with a genuinely affordable retail price, I not only saved a bunch of time but a lot of cash as well. So take a look-you may well discover that the way I solved my exhaust system dilemma will work for you too!
Here's where I started out-a...
Here's where I started out-a pair of Patriot (Ford) and a pair of Sanderson (Chevy) lakes-style headers (one mine and one my pal Tim's) and a great idea of how I wanted to go about retaining their good looks while not getting ticketed by the local highway patrol for excessive noise.
The Car Chemistry Insert Kits...
The Car Chemistry Insert Kits (for lakes-style headers anyway) consist of a pair of center core inserts, flanges, and a series of drilled rings whose graduated diameters fit tightly against the walls of the header cone. The design, size, and placement of the perforations are by no means random; they're the result of testing that ensure an acceptable note and impressive performance.
Like I keep saying, this is...
Like I keep saying, this is an extremely easy job. The instructions are clear and the assembly is really straightforward-which is great if you're a wannabe fabricator like I am. Assembly begins by determining the outlet end of the main core tube and readying the smallest (in this case the 3-inch) ring for placement on it. Car Chemistry marks the inlet and outlet sides of the core tube so pay attention and make sure you begin on the inlet side of the tube. The first disc is pressed or driven onto the core tube (a section of 2 1/4-inch pipe works great) downward toward the bottom of the tube.
The instruction sheet noted...
The instruction sheet noted that the first disc should fall roughly between the second and third port of the header-on both the spacing worked out perfectly-the first discs landed where suggested and the core tubes ended up right at the end of the header bell.
With the first disc located,...
With the first disc located, I marked the core tube with a Sharpie just in case I moved it while installing the next disc-that way if I did I could move it back into the correct position. The next discs/flanges came next, and I installed them the same way as I did the first. By the way, the discs/flanges do go onto the core tube relatively tightly, but not overly so-and they can be adjusted so they make good contact with the header while work progresses.
I should mention, unlike the...
I should mention, unlike the baffle kit I used on my first installation a year or so ago (Speedway lakes-style headers for a Ford Flathead), the baffle kits I used this time around included end cap discs equipped with integral flanges. This worked out perfectly for both the brands of headers I was working with this time.
Since there are basically...
Since there are basically three different triangular-style flange sizes used on headers these days we had ordered the largest version, which if my memory serves me correctly were 3 1/2 inches-which matched the Sanderson headers perfectly, as you can see. I slid the disc/flanges over the core tubes, inserted the assemblies into the bell of the headers, and then tapped the core into the bells until the inner discs contacted the inner wall of the headers. Once they were correctly located, I carefully removed the assemblies from the headers and tack-welded the discs to the core tubes.
With the baffle assemblies...
With the baffle assemblies for the first set of headers (Sanderson's) assembled and welded together the next step was to wrap the baffles with the combination of stainless wool, 'glass cloth, and a single layer of aluminum foil (to help hold the material in place during installation) for added noise reduction.
With the packing installed...
With the packing installed around the baffles the next phase was to bolt the assemblies to the Sanderson small-block Chevy headers and fab a pair of caps for the secondary exhaust outlets.
Using a cardboard template...
Using a cardboard template I traced the shape of the Sanderson outlets and transferred the shape to a sheet of steel plate-twice. I then cut them out, drilled them for mounting bolts, and closed up the secondary outlets.
With the first set of headers...
With the first set of headers completed (in about an hour) it was onto the Patriot headers for the small-block Ford. The process is basically the same with the exception of the caps/flanges. The Patriot headers are designed with round-shaped flanges rather than the more triangular shape we've become used to-but, with the Car Chemistry baffle kits this wasn't a big problem.
All I did to make the Car...
All I did to make the Car Chemistry baffle kit work with Patriot's was to cut the original circular flanges off the header bells with a cut-off wheel-right at the weld where the round flanges met the bells-with the intention of welding the new fully assembled Car Chemistry baffles right to the Patriot bells.
So, I assembled the second...
So, I assembled the second set of baffles in the same manner as the first Instead of bolting the end cap/flange to an existing header flange I just slid them into place and welded the baffle assemblies to the Patriot bells.
The final step for the afternoon's...
The final step for the afternoon's task was to fabricate caps for the Patriot secondary exhaust flanges as I'd done for the Sanderson headers.
And there you have it ......
And there you have it ... two pair of lakes-style headers of different heritage both equipped with Car Chemistry baffle kits that allow us to run header-only systems without gloveboxes full of tickets penned by local law enforcement.