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Finally, a header solution for 16V AW11s! [Archive] - Toyota MR2 Message Board

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Finally, a header solution for 16V AW11s! [Archive] - Toyota MR2 Message Board Toyota MR2 Message Board > Welcome To The Toyota MR2 Board! > MR2Board Sponsors > SV3 Power Products > Finally, a header solution for 16V AW11s! PDA

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te51levin02-09-2013, 10:08 PMUPDATE: Header service is now in the catalog!

20V Header Modified to fit 16V 4AGE [EX14W] - $67.95 : SV3Power.com, custom MR2 exhaust components (http://www.sv3power.com/store/index.php?main_page=product_info&cPath=71&products_id=208)

From the SV3Power blog (http://www.sv3power.com/?p=476) -

As promised, here's the newest addition to the SV3Power catalog. I'm now modifying 20V headers to fit 16V AW11s! This is an OEM Toyota 20V header, extended to clear the front-mounted starter on a naturally aspirated 4AGE, and fitted with my dual-pattern flange so it will fit both the 16V and 20V 4AGE cylinder heads. Since this is an extended 20V header, it will work with an extended version of my 20V-to-AW11 adapter downpipe, which will soon be added to the downpipe catalog.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod13.jpg


Pricing has not been cemented yet, but I will be offering these headers on some sort of exchange basis. In other words, the customer can send me a stock header as partial credit toward the purchase of a modified header, or can send me a stock header after purchase for refund of the core/exchange fee. That should allow me to maintain a supply of parts on hand.

This is pretty big news since so many first-generation MR2s have cracked cast iron exhaust manifolds and rotten downpipes. Now they can replace the cracked manifold and nasty downpipe at the same time, and gain some performance at the same time.

This will be offered for both the Silvertop and Blacktop headers, with the Silvertop being preferred for NA cars and the Blacktop header more ideal for Supercharged cars or well-modified NA engines. I'll also be adding options for EGR bungs in both stock locations.

If you're interested in how this work is done, here are some photos.

First, the stock flange must be removed from the 20V header. A fence clamped to the bandsaw keeps the cut straight and ensures that each tube is cut at exactly the same distance from the mounting surface.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod01.jpg


Here's the header with the flange cut off. All four tubes are cut in a nice, straight line.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod02.jpg


To extend the header, four identical lengths of tubing are cut on the bandsaw. Since this is an AE101 (Silvertop) header, 35mm OD tubing is used to match the inner and outer diameter of the header's original tubes.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod04.jpg


The four extensions are tacked in place on the header. Note that the header and extensions are both beveled to provide for better weld penetration.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod06.jpg


Now the new flange slides over the extensions If this was an AE111 (Blacktop) header, the tubes would be too large to fit through the flange, and would be welded to the outer face of the header instead.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod07.jpg


The header is now attached to the jig. A locating plate secures the outlet flange in the correct location, and the nuts at the header flange pull the flange just to the end of the extension tubes.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod08.jpg


With the header on the jig, the flange is tacked to the extensions. The header is then removed for final welding. By welding short lengths at a time and moving frequently, distortion is avoided.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod09.jpg


Here's the back of the flange. Note the flush fit of the extension and the thick-wall tubing that matches the OEM dimensions perfectly.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod11.jpg


And here's the final product - a 20V header, extended to fit over a front-mounted starter, and ready to bolt up to either a 20-valve or 16-valve 4AGE.

http://www.sv3power.com/wp-content/uploads/2013/02/headermod12.jpg


It doesn't look all that different until you compare it to a stock 20V header. Here they are side by side:

http://www.sv3power.com/wp-content/uploads/2013/02/headermod14.jpg


Still not the best pic, but you can see the difference.

That's enough for now. Let me know what you think! PushFromBehind02-09-2013, 10:42 PMAwesome! I may be contacting you soon! MisterDuo02-09-2013, 11:03 PMis the process for using an ae92 header different? te51levin02-09-2013, 11:16 PMNot sure I understand. AE92s use the same cast iron manifolds as AW11s. MisterDuo02-09-2013, 11:35 PMoh really? i thought the fitment was slightly different between the ae92 and aw11. Senior Oso02-10-2013, 12:34 AMGlad to see you're still making awesome parts! just curious but have you tried it on your test mule? Did it have any effect on power output? Nine-Breaker02-10-2013, 01:20 AMoh really? i thought the fitment was slightly different between the ae92 and aw11.
You must be thinking of aftermarket parts such as OBX. Factory manifold's part number is exactly the same as I found out earlier.

Looks great though, Aaron! te51levin02-10-2013, 01:41 AMGlad to see you're still making awesome parts! just curious but have you tried it on your test mule?No, unfortunately not. I had to sell the mule last month. But if anyone's able to perform any back-to-back dyno testing, I'd be up for some sponsorship. I have a feeling there is quite a bit of power potential here. Senior Oso02-10-2013, 05:17 AMIf i had an aw11 I would try this out. Hope all goes well testing it out. Also hope you're doing good with all your projects! Walley102202-10-2013, 10:04 AMGreat job Aaron! I have a BT header laying in the garage collecting dust. If you start buying these, let me know. ^.^ thurmonster02-14-2013, 01:26 AMI'll test this out at Track Forged dyno for ya Aaron, I've been looking forward to a 16v header, I'll be gettin the down pipe too soon Zarek02-14-2013, 04:03 AMHow would themanifold trade work for people with the 16v? You can't use the 16v manifold can you? Also looking forward to seeing what the price is. Perhaps a group buy to kick things off? mr220v02-14-2013, 10:15 AMFrom what I remember, the 16v flange would interfere with the water inlet on the back of the 20v head. Does yours do this? It looks like it might not. te51levin02-14-2013, 01:22 PMI'll test this out at Track Forged dyno for ya Aaron, I've been looking forward to a 16v header, I'll be gettin the down pipe too soonWe need to talk about this. It may be a good idea but I'd need to be certain that the testing is as objective as can be...otherwise I'd be better off doing it here with my own testing methods.

You will need both the header and downpipe to work together.



How would the manifold trade work for people with the 16v? You can't use the 16v manifold can you? Also looking forward to seeing what the price is. Perhaps a group buy to kick things off?The point of this is to eliminate the 16V manifold and stock downpipe, and replace them with the extended/modified 20V header and SV3Power 20V adapter downpipe. You'd need to find a 20V header and have it shipped to me for modification.

I will not be conducting any group buys. They are fine for mass produced items that are all identical, but do not work well with my build method.



From what I remember, the 16v flange would interfere with the water inlet on the back of the 20v head. Does yours do this? It looks like it might not. Mine has been redesigned to clear the water outlet. I have not yet heard back from any buyers but I believe it offers all the clearance you would need. Zarek02-14-2013, 02:11 PMOk cool deal thurmonster02-16-2013, 09:22 PMSo how much we looking at for the header & row pipe package for 16v te51levin02-16-2013, 11:31 PMDownpipes vary by configuration, and you can price them out on the website. The header mod will start around $70 with exchange when I get that online. thurmonster02-26-2013, 11:23 AMI don't have any componets as if right now, I would be buying all new. te51levin03-03-2013, 06:26 PMthurmonster, I don't think that would work for a back-to-back comparison.

I've just added the 20V header modification to the catalog!

20V Header Modified to fit 16V 4AGE [EX14W] - $67.95 : SV3Power.com, custom MR2 exhaust components (http://www.sv3power.com/store/index.php?main_page=product_info&cPath=71&products_id=208)

You can now order the modified 20V header and matching 20V-to-AW11 adapter downpipe the way you want them, send me your 20V header, and I'll modify the header and build the downpipe to work together in your 16V AW11.

This should generate some orders. There has been a real lack of affordable headers for these cars for a very long time. palos03-03-2013, 07:25 PMThe following link indicates that the exhaust manifold is the same for the MK1b (except '87): http://mr2.zhutiblog.com/com/forums/lithia-toyota-springfield/Toyota-MR2-55168-search-first-mki-exhaust-manifold-related-parts-list.html

Is the reason that you have not advertised these for the 4AGZE is that you don't have an extended downpipe available for the SC? te51levin03-03-2013, 07:45 PMThe following link indicates that the exhaust manifold is the same for the MK1b (except '87): I'm not sure what you mean, but if there is any confusion, there were only two different cast iron manifolds on AW11s. As that link states, '85-'87 cars used the early manifold with top feed EGR port, whereas all '88-'89 cars (whether NA or SC) used the later manifold with side feed EGR port.



Is the reason that you have not advertised these for the 4AGZE is that you don't have an extended downpipe available for the SC?I didn't mean to exclude the 4AGZE by any means! There is absolutely no reason the modified 20V header will not work on a supercharged car, so long as it is combined with an extended 20V-to-AW11 SC downpipe to match the larger SC catalytic converter. All my 20V-to-AW11 downpipes now offer the option to extend them to work with the new extended 20V header. You can order what you need for pretty much any combination. thurmonster03-04-2013, 10:07 AMAre you still making headers? I can't find it on the site te51levin03-04-2013, 10:38 AMIf you just go to sv3power.com, that's the blog, and you can click the Products tab to go to the store. Then click the category marked Headers.

The link directly to the header was posted in the #1 and #19 posts in this thread:

20V Header Modified to fit 16V 4AGE [EX14W] - $67.95 : SV3Power.com, custom MR2 exhaust components (http://www.sv3power.com/store/index.php?main_page=product_info&cPath=71&products_id=208) thurmonster03-13-2013, 12:27 AMSo, first I need to "find" a 20V header somewhere on the web, then send it to you for the modification? te51levin03-13-2013, 09:58 AM^That's correct. p0x1c d15c003-31-2013, 06:43 PMHey aaron, you have any jdm suppliers it there that you could give us info on? If we buy out there and ship it to you to do the header work, total cost would be reduced. Just a thought i had... What do you think? te51levin04-01-2013, 04:24 PMThere are no engine importers around here that I'm aware of. The best way to go is to buy a 20V header from someone who can't use it, like an AE86 owner. You can have them ship it to me rather than shipping it to you first and then on to me. Powered by vBulletin® Version 4.2.5 Copyright © 2026 vBulletin Solutions Inc. All rights reserved.

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