Engine

Headers & exhaust

Headers depend on ride height. For stock height or a drop of about 2 inches, use Hedman Elite HTC 1-3/4 inch long tubes with 3 inch collectors, 63820 (black, $933.99) or 69820 (silver, $870.99). Truck long tubes hang about 4 inches below the frame. For a deeper drop, use Hedman mid-length 69170/69176 (HH626-V from…

Research date 2026-10-12. Prices are from search-result snippets and fetched vendor pages, labelled with source. Summit and Jegs block page fetches, so several prices come from snippets only. Anything I could not confirm is marked "not confirmed".

The pick

Good
Headers $490-$610 (Hedman 69111 $609.99 confirmed; 69110 price not confirmed; Patriot 806-V from $430 unconfirmed). Flowmaster 17742 kit about $1,000-$1,070 (Eckler's $1,065.95, out of stock), plus about $100-$300 for 2.5 inch Super 50 or better mufflers. Header-back pipe fabrication is extra. Total about $1,600-$2,000.
Better
Hedman Elite 63820/69820 at $871-$934, or mid-length 69176 (price not confirmed; HH626-V from $437) if the truck is dropped. Custom 2.5 or 3 inch stainless dual with an H-pipe or X-pipe, about $1,000-$2,000+ (labor-driven, not confirmed), with Super 50 or Dynomax mufflers at $200-$300 a pair. Total about $2,300-$3,500.
Best
Hedman stainless T304 with silver ceramic, 62826, about $1,299 (unconfirmed snippet). Custom 3 inch 304 stainless dual with Borla Touring mufflers (about $286-$570 a pair, part number 401661 or 401663), resonators and weld-in O2 bungs. Exhaust quote not confirmed. Total about $3,500-$5,000+.

Headers: Decide ride height first. For a truck at stock height or a mild (about 2") drop: Hedman Elite HTC 1-3/4" long tube, 63820 or 69820 (about $870-$934), 3" collector. Reasons: confirmed 1968-87 BBC truck 2WD/4WD coverage, factory ceramic, 14 ga tubing, 3/8" flanges. Caution (corrected in verification): the forum evidence that headers "tuck up in the frame" refers to car-style (Nova/Chevelle) Hedman headers [20], not these truck tubes, which hang about 4" below the frame and were reported 1.5" off the ground on a lowered truck [42]. If the owner drops the truck further (3"+), the better bolt-in is the Hedman mid-length 1-3/4" 69170 / 69176 (price not confirmed; HH626-V from $437), or car-style long tubes. If budget matters, the uncoated 69110/69111 at $490-$610 (69111 confirmed $609.99, 69110 price not confirmed) plus Jet-Hot ($275) lands in the same place [23]; 69111 also carries CARB E.O. status. If the truck is being lowered with drop spindles and the owner wants maximum ground clearance, a Hedman/other "Nova-style" 68-72 car header is the proven alternative on lowered C10s [20][34], at the cost of clutch-linkage and steering shaft tweaks.

Skip 2" primaries and the Hooker 2841 for this build. Skip Doug's Tri-Y: its own copy says power runs off idle to about 4,500 rpm, short of the 5,500-6,000 rpm goal, and it does not fit side-bellhousing-mount 4-speeds (moot with a T56 hydraulic clutch).

Exhaust: For the "mean but livable" goal and the owner's stated spec, go dual 3" mandrel stainless with an X-pipe, over-axle routing, Flowmaster Super 50 or Dynomax Ultra Flo SS or Borla Touring mufflers, plus a pair of 3" resonators (add them in the first build if the budget allows; otherwise they bolt in later if drone shows up at 65-70 mph). This is the owner's path and it is the project default. The H-pipe is an option, not the default: the Jalopnik article cited at [46] (fetched 2026-10-12) says H-pipes eliminate drone and emphasize deeper bass tones while X-pipes sound higher-pitched and smoother (it gives X-pipes 2-4 hp more than an H-pipe), and Pypes' own page (fetched) says an H-pipe gives a deeper, more traditional muscle-car note and an X-pipe a smoother, higher-pitched, sometimes raspier one, adding that in most street cars you hear the difference more than you feel it. A third source (a search summary of fmsperformance/Holley/others) says neither crossover eliminates drone. This is a contested, taste-driven area resting on manufacturer and magazine opinion, not measurement; muffler choice matters more than crossover choice at 2,000 rpm cruise [25]. So: build the X-pipe (owner's pick), put resonators and a non-drone muffler (Super 50 / Ultra Flo / Touring) on it, and swap in an H-pipe section only if the tone or drone is unacceptable. In practice:

  • If the owner wants a kit (2.5" H-pipe; budget path, Recipe 1): Flowmaster 17742 (still needs header-back pipes fabricated; see table) but replace the Super 44 mufflers with 2.5" Super 50s (stock 44s are the drone offenders for interstate commuting) [25]; or the Pypes SGT978SE for stainless.
  • If the owner wants a custom 3" dual (preferred for T56/4L80E and a drop): have a shop build it after the engine and transmission are in.

Depends on other systems: If 4L80E, put the transmission crossmember and X-pipe in the same planning pass; the 4L80E is physically longer and a Hooker BlackHeart LS/LT-swap crossmember for the C10 is advertised for 3" duals [35] (CJ Pony page returns 403, so the exact claim and fitment were not rechecked). If TH400, the stock-style 2.5" kit fits as designed.

Why it matters

The '77 Bonanza is a 73-87 square-body C10 with a Mark IV 454, power steering box, factory A/C bracketry and a frame designed around a ~1970s big block. Headers are where the packaging fights happen on these trucks. The long-tube tubes pass the steering box and idler/linkage on the driver side, crowd the starter and oil filter, sit close to the upper control arm nut, and (with a manual trans) hit the clutch Z-bar. The owner's goals (T56 or 4L80E possible, drop spindles, mean-but-livable sound, ~35 min interstate commute at 65-70 mph) make the exhaust a drone-management problem as much as a power one.

The most important finding: Hooker has no current 73-87 big-block truck long tube that I could confirm. Hooker's Super Competition 2841HKR / 2841-1HKR (2" primary, 3.5" collector) are listed for 1968-74 trucks (the 73-74 overlap is the only square-body fitment shown) [3][4] (reverified: Billy's page says 1968-1974). Note one forum owner of an 84 K10 praised "Hooker Competition" headers for #6 plug clearance [40], so an older Hooker truck header exists; no current 75-87 BBC part was found. Hooker's 1973-87 C10 headers in the cjponyparts catalog are LS-swap parts [5]. So "Hooker Super Comp" is not a clean bolt-in for a 1977 BBC truck. Real 73-87 BBC truck long tubes are Hedman, Patriot, and Doug's (Tri-Y). Also, a 454 at ~10.3:1 with a lope-leaning cam and a 5,500-6,000 rpm limit is a "torque" engine, so primary size should lean 1-3/4 to 1-7/8", not 2".

On exhaust: nearly every off-the-shelf kit for 73-87 2WD trucks is 2-1/2" (Flowmaster American Thunder, Pypes, FlowTech) [11][12][19]. A true 3" mandrel dual with X-pipe for BBC headers is mostly a fabricate-it or custom-shop job (the Speed Engineering 3" kit is explicitly LS/LT only) [14]. 2-1/2" per side is commonly judged adequate for ~450-500 hp NA and is quieter (no engineering source for the hp-per-size claim was retrieved; it is a rule of thumb), so 3" is a want rather than a need for the 489; but it is the owner's stated spec (dual 3" with an X-pipe), and nothing found says 3" hurts a ~500 hp engine, so the project path is the owner's: custom dual 3" with an X-pipe plus resonators, with the kit/H-pipe routes below as options.

Options

Headers (big-block, 1973-87 2WD truck)

Tier Brand & model Part # Price (vendor, checked 2026-10-12) Link Notes
Good Hedman Hedders standard-duty uncoated, 1-3/4" primary, 3" collector 69110 (68-91); 69111 (67-91, A.I.R. bosses) 69111: $609.99 (CJ Pony search snippet, rechecked 2026-10-12; MSRP shown $1,218.57 is inflated); an earlier $489.99 Jegs snippet was not reconfirmed. 69110: price not confirmed (an earlier $794.09 figure had no identifiable vendor; treat as unreliable) [8][9][10] Gasketless ball-and-socket collector. Hedman's listing: 69110 fits 1967-87 C10/C20 2WD (a Berry Performance title says 68-86 2WD / 68-81 4WD; confirm year range on the box). 69111 is the A.I.R.-boss version and is listed as CARB E.O. (50-state legal); 69110 and the Elite/stainless parts below are labelled "not legal for street use on 1975 and later" by Hedman. KC-metro emissions-inspection rules for a 1977 were not checked. Widest truck coverage; forum users report "great fit, tuck up in frame" for Hedman Nova-style headers on a 454 C10 [20]. A JEGS reviewer on a '69 C10 had to dent a primary for the upper control arm nut [10]. Prices vary a lot; shop around.
Good Patriot Exhaust 1-3/4" long tube, ceramic finish, 2-1/2" reducers, 3" collector 806-V from $430.46 (CJ Pony snippet) [6] Catalogued 1973-87 C10 396-502 BBC (described in the CJ listing as round-port flanges - which would NOT match the square exhaust port of the Edelbrock 60455 (see the port-shape note below); do not buy for that head until Patriot confirms - 2-1/2" reducers, 3" collector, 18 ga). No fitment reports found. Ceramic-finish durability and break-in coating care unverified. 18 ga is thinner than Hedman Elite 14 ga, so the "Good" tier makes sense.
Better Hedman Elite HTC (black/silver ceramic), 1-3/4", 14 ga primaries, 3/8" flanges 63820 (Black Maxx); 69820 (silver) 63820: $933.99; 69820: $870.99 (CJ Pony snippets; "MSRP" shown is inflated) [8][7] Same fit as the standard line (2WD/4WD, 1968-87, 2-1/2" reducers, 3" collector, gaskets included), thicker steel, factory ceramic (rated to 1,400 F). Prices rechecked via search snippets 2026-10-12: 63820 $933.99 (MSRP shown $1,921.69, inflated). Best value for a coated header at stock ride height.
Better Hedman long tube, 2" primary, 2WD only HH632-V (CJ Pony SKU; Hedman number not confirmed) from $476.26 (CJ Pony snippet) [8] Only if you expect to spin the engine well past 5,500. Likely too big for this build (see primary size discussion below).
Better (lowered/dropped truck) Hedman mid-length, 1-3/4" primary, 3" collector, 14 ga, 3/8" flange 69170 (uncoated); 69176 (silver HTC ceramic); CJ Pony SKU HH626-V HH626-V from $437.46 (search snippet; which finish this price is for was not stated); 69176 price not confirmed [50][51] Added in verification: Hedman launched these specifically for big-block C10/C20s (1967-87, 1/2- and 3/4-ton) because truck long tubes drag on lowered trucks; "mid-length" keeps the collector up tight to the body above the frame rail and eases steering-box clearance. Gives up a bit of top-end versus a full long tube, a fair trade for a 5,500-6,000 rpm torque-biased 454. This is the product to look at if the owner picks a 2"+ drop.
Reference only (not recommended) Doug's Tri-Y, 1-3/4" primary, 2-1/2" collector, metallic ceramic D303Y (black: D303Y-B) $1,088.77 (Pertronix); $979.89 (CJ Pony snippet) [15][16] 16 ga, 3/8" flange, 1968-91 trucks; page says they need big block frame stands and motor mounts and "do not fit 4-speed with factory side bellhousing mounts" (T56 swap issue). Tri-Y is a torque-biased street design: CJ Pony's description says it makes its power "from off idle to 4500 RPM", which is below this build's 5,500-6,000 rpm goal. Pertronix page also carries an odd "A/C equipped models only" note. Closed-course/pre-emissions legal wording applies.
Best Hedman stainless T304 with silver ceramic 62826 $1,298.99 (CJ Pony snippet; shown MSRP $2,937.74; not rechecked on the vendor page, which returns 403 to fetch) [13] CJ Pony's title lists 68-87 2WD/4WD (one vendor description says 1968-77), either way it covers this truck. T304 stainless, polished silver HTC ceramic, 3/8" flanges, 2-1/2" reducers, 3" collector. Coating-proof, long-term bulletproof option. Same 1-3/4" primary.
Reference only Hooker Super Competition, 2" x 35" primary, 3.5" collector (painted / ceramic) 2841HKR / 2841-1HKR not confirmed in USD; UK listing £551.99 sale / £1,090.99 regular (Billy's) [3][4] Listed 1968-74 trucks only. Do not assume 75-87 fit. Collector is oversized for this build.
Reference only Speed Engineering LS/LT 1-3/4" and 1-7/8" long tube n/a n/a [14] LS only. Not for a BBC.

Primary size: Century Performance (fetched) says a mild 396-454 BBC wants a minimum of 1-5/8" to 1-3/4", with bigger tubes reserved for 6,500+ rpm [18]. The Speedway tech page [17] returned no content on fetch, so the "1-3/4 to 1-7/8 for 400-500 hp" range is not independently confirmed here. Our engine is 540 ft-lb leaning, so 1-3/4" is defensible; if the owner goes with the full 500+ hp aluminum-head build and wants to pull hard to 6,000, a 1-7/8" long tube is worth asking about (no BBC-truck 1-7/8" Hedman part was found). 1-3/4" primary, 3" collector is the correct pick; it also tucks tighter.

Header flange / port shape (integration pass, search-summary level only): the Edelbrock Performer RPM oval-port heads (60435/60455) are described as having a square exhaust port in standard (OEM) location; the Hedman mid-length HH626-V (69170 / 69176) is described in CJ's listing as made for factory-profile heads with a square exhaust port. Raised-port heads (AFR 265/290/300 at +0.375", Trick Flow PowerOval at +0.300") are not addressed by any listing for the Hedman Elite 63820/69820, standard 69110/69111 or Patriot 806-V, so they are a fit gate (section 02). Holding a header flange gasket against the actual port is the only confirmation; none of these shape claims was read from a fetched vendor page. The Remflex 2030 described below is the 'irregular stock port' gasket; it matches only if the head's port is that shape.

Gaskets: Remflex 2030 (BBC "2"w x 1-7/8"h irregular stock port", 2-piece, graphite) is $45.85 at stainlessheaders.com [21]; Remflex states "do not bend", 20 lb-ft. Port shape must match the heads: Mark IV iron stock ports vs aftermarket aluminum rectangle ports (Remflex lists other BBC sets, e.g. 2013 large race round, 2047, 2068) [21][22]. Match to the actual cylinder head before ordering.

Shorty vs long tube: Shorty headers hold up fine for street big blocks where ground clearance and fitment matter, but long tubes win above ~4,000 rpm [18]. With a drop and 5,500+ rpm goal, long tubes are justified; just buy car-style (Nova/Chevelle) clearance if the truck is lowered (see gotchas).

Coatings: Jet-Hot has been quoted at about $165-$279 for a pair in Sterling silver, with extra for black [23]. Factory ceramic from Hedman Elite or Doug's avoids that. Ceramic coatings need a cast-manifold break-in on a fresh engine (Hooker warns in its listing) [4].

Exhaust (header-back / crossmember-back)

Tier Brand & model Part # Price (vendor, checked 2026-10-12) Link Notes
Good Flowmaster American Thunder, 73-87 C10/C20 2WD, 2.5" aluminized, Super 44 mufflers 17742 Eckler's page (fetched 2026-10-12): $1,065.95, out of stock. JBS Power Centre (fetched): $1,449.93 (retailer is likely non-US; currency not confirmed; special order, 10+ week lead). Earlier Flowmaster-site $921.95 / Speedway $1,024.95 / LiftKits4Less $999.95 / $819.86 figures could not be rechecked (403) and should be treated as unconfirmed. Realistic US street price $1,000-$1,070 [11][24] Read the fine print: vendors differ on whether this is crossmember-back or header-back (Eckler's/Flowmaster say crossmember-back; CJ Pony/JBS say header-back). JBS states it is not a direct bolt-on and requires fabricating pipes to connect to the headers. 2WD only, covers long/short wheelbase, auto or manual, not for cat-equipped trucks. Dual with H-pipe, 3-yr warranty, aluminized (rust over decades). Super 44 is the drone-prone muffler for highway cruising [25]. Swap to 50 Series for this truck.
Good Pypes crossmember-back 2.5" side exit, H-pipe, Street Pro mufflers, 409 stainless, for 1975-87 V8 C10 SGT978SE price not confirmed (a related Pypes 75-87 GM crossmember-back X-pipe kit, SGT980E-FSJC, was found at $1,133.79 on a search snippet; forum quotes ~$1,100 for Pypes 2.5" 2WD kits) [12][19] The only stainless kit with 75-87 coverage I found; CJ Pony page returns 403 so the exact SGT978SE listing could not be rechecked. Side exit. Crossmember-back, so header-back pipes still need to be built.
Good FlowTech 2-1/4" manifold-back kit 52525FLT ~$200 for the kit (forum report only, 2WD/4WD fit varies) [19] Budget. Not recommended for a 450+ hp engine.
Better Custom/fab 3" or 2-1/2" mandrel from a local exhaust shop, 304 or 409 stainless, X-pipe, over-axle n/a labor-driven; not confirmed (forum builders quote ~$1,000 for a custom 2-1/2" job) [19] Route to clear a T56/4L80E crossmember and a drop. Pair with Hooker BlackHeart crossmember if LS-swap style crossmember wanted (up to 3" duals).
Best 3" stainless dual with X-pipe and tuned mufflers (custom) n/a kit price not confirmed [14] Speed Engineering 25-1060 ($399.99 from PSI, 3" 304 SS, axle dump) is LS/LT only; do not buy for a BBC [14].

Mufflers (3" inlet where noted)

Muffler Part # Price (vendor, checked 2026-10-12) Link Drone notes
Flowmaster Super 50 (3" ctr in / 2.5" dual out) 530552 $301.48 sale (JBS Power Centre; regular $330.86; likely non-US retailer, currency not confirmed; special order). Listed there as the 1988-93 GM truck muffler [26] Muffler inlet must match the pipe: the 17742 kit is 2.5", so Super 50s for it must be the 2.5" in/out versions (part # not confirmed); the 3" parts below are for a custom 3" system. "Mild to moderate" tone; 3-chamber, aimed at big blocks. Forums: 40/44 drone on highway, 50 is quieter [25].
Flowmaster Super 50 (3" ctr/ctr or offset/ctr) 53055 / 53056 53055 is $204.95 on Flowmaster's own page and Walmart ($184.45 and $199.95 seen at other retailers; checked via search snippets 2026-10-12); 53056 price not confirmed [27] Same family.
Flowmaster Super 50 409S stainless 8530552 $224.95 (snippet) [27] Stainless version.
MagnaFlow 4x9 oval stainless, 3" 14319 / 14329 $169 / $180 (Jegs) [28] Straight-through; moderate.
Dynomax Ultra Flo SS 17220 (center) $107.47; 17235 is $226.99 (snippets) [29] Reviews: "nice low mellow rumble, almost no drone" and 4.61/5 on 33 reviews [29] (review page not rechecked; Jegs blocks fetch). 14" body, all-409 stainless; a short muffler, so expect it louder than a Borla Touring or Super 50 on a big block.
Hooker Max Flow 3" offset/center 21605 $140.35 (Jegs snippet) [30] Straight-through; likely loud.
Pypes Race Pro 958-MVR44 (3.5") $130.79 (Jegs snippet) [30] Straight-through; 2.5" and 3.5" variants shown, not 3" confirmed.
Borla Touring (3" ctr/ctr, 24" body, T-304, un-notched) 401661 per Penguin Garage; other retailers list the un-notched as 401663 (notched 401662): verify before ordering $285.99 sale (Penguin Garage, fetched 2026-10-12; sold out); $569.95 at another retailer [31] Quietest Borla; long body suits trucks.
Borla Pro XS (3" in / 2.25" or 2.5" dual out) n/a $187.99 - $194.99 (snippets) [32] Moderate-loud.
Spintech n/a ~$245 (eBay snippet); one buyer paid $112 shipped [33] Users: nice tone, not droney vs Flowmaster 40, though one cruise-rpm complaint.

Fitment & gotchas

  • Steering box (power steering gear): The big concern for 73-87 BBC. A PS box is roughly 5" at its widest, with manual steering boxes giving more clearance [36]. Forum users on '79 and '80 trucks report headers "clear the frame, starter and the steering" [37]; others hammer/torch a dent for clearance. Check your box with a mock-up before you pay for coating.
  • Upper control arm nut and idler: a JEGS reviewer had to dent a primary to clear the upper control arm nut on a '69 C10 [10]. Expect the same on a drop-spindle truck.
  • Starter: the driver-side primary is close to the starter. Solutions: reflective wrap, heat shield, hammer clearance, or a gear-reduction starter [38][39]. Chevy's starter position is "prone to heat soak, especially with headers" [39]. One user got ~1-1/2" of gap with a smaller Delco starter (Delphi R613326B from a 1999 Suburban) [39]; ~$400 for a Mean Green is quoted. Plan on a wrapped gear-reduction starter regardless.
  • Oil filter and dipstick: driver-side header can contact the oil filter. Short filter or remote relocate [34][40]. Dipstick tube may need bending.
  • A/C bracket: some headers require A/C compressor bracket modification [40]; Patriot sells a header A/C bracket for C10 (H7608, small block listing) [5]. The factory A/C truck's compressor sits on the passenger side; check the passenger primary against it.
  • Clutch linkage (T56): a Z-bar clutch needs minor clearance [41]; with a hydraulic clutch (typical T56 conversion) the issue goes away. Doug's warns about factory side bellhousing mounts [15].
  • Ground clearance when lowered: truck long tubes hang ~4" below the frame, car headers tuck closer [42]. A member switched from truck headers to car headers after lowering because the tubes hung "about 1.5 inches off the ground" [42].
  • Frame stands / motor mounts: BBC needs the big-block frame stands and mounts [15]. Check what the truck has.
  • Spark plug boots: use HEI-rated boots; cylinder #6 is the tight one [40].
  • Break-in: install cast manifolds or accept a ceramic-coating warning during first fire [4].
  • Tailpipe routing: Over-axle with angled tips was the preferred routing on gmsquarebody (avoids turndown dust and pavement heat) [43]; the OEM under-bed spare tire is the main obstruction on 73-87 trucks [44]. A drop in the rear (flip kit/c-notch) changes this entirely.
  • Rack-and-pinion: Performance Online's $2,374.60 73-87 rack kit notes "quite a bit of room for the shaft support, but some headers may require modification" [45]. The rack route improves, not guarantees, header clearance.

How it touches other systems

  • Steering conversion: a rack or quick-ratio box (Borgeson) changes the header clearance picture completely; decide the steering box before ordering headers.
  • Drop spindles: affect the upper control arm nut location and ride height (header clearance to ground) [34][42].
  • Cam: the rougher the idle, the more the exhaust (collector size and X-pipe vs H-pipe) shapes the lope; H-pipes are described (Jalopnik, Pypes) as giving a deeper tone and X-pipes a higher, smoother pitch; whether either tames drone is contested and taste-driven, and muffler choice matters more [46][25].
  • Power brakes: a lumpy cam bleeds vacuum; mufflers do not affect this but a vacuum pump would also sit on the driver side near the header.
  • EFI vs carb: EFI needs O2 bungs plus 18" of straight pipe downstream of the sensor [47]; see O2 section below.
  • 4L80E / T56: crossmember relocation and pipe routing; a Hooker crossmember advertises 3" dual clearance [35] (not rechecked).
  • Starter and wiring: starter heat soak is influenced by header primary placement [38][39]; plan to wrap the solenoid wire.
  • Cooling: headers lower underhood temperature if coated; coating helps with starter and A/C lines too.
  • Gearing/tires: 65-70 mph at ~2,000 rpm is where drone peaks; muffler choice matters more than header choice here [25].

O2 sensor bungs (wideband and EFI): Best practice per Holley is in the collector or 1-10" past it (so all cylinders mix) with the sensor between 10-2 o'clock (never bottom) and at least ~18" of pipe after it for Holley Sniper 2 [47][48][49]. (Source [47], the Engine Labs page, is now dead, HTTP 410; the same Holley guidance appears in the forum threads at [52].) For a carbureted tuning wideband (Innovate LC-2 or AEM X-series) weld one bung per side just behind each collector 6-12" from the flange, or one in the post-X-pipe if you want a single sensor. I did not find a header with bungs installed on the BBC truck line; plan on adding bungs yourself (ask the coater to plug them before coating). Hedman does not advertise bungs on these parts.

Check on the truck

  1. Is the steering box the factory power box, and is it staying? (Rack-and-pinion changes header choice.)
  2. Final transmission choice (TH400 / 4L80E / T56)? It sets crossmember position and pipe routing.
  3. What drop (2" vs 2.5" spindles, rear flip or notch)? Determines car-style vs truck headers.
  4. Is the engine staying on stock heads or going to aluminum heads? Header flange port shape and gaskets (Remflex 2030 vs race rectangle) follow the heads.
  5. 2.5" exhaust is the practical off-the-shelf kit size; the project default is the owner's custom 3" dual with X-pipe and resonators. Cost allowance (E): fabrication $1,200-$3,500+ per a Shawnee shop's own published price list (section 19, self-published), plus headers and mufflers.
  6. Confirm big-block frame stands and motor mounts are on the truck (the frame wearing a small block originally?).
  7. Is the A/C compressor mounting going to be factory? Check bracket clearance against passenger primary.
  8. Is a gear-reduction starter acceptable?
  9. EFI or carb? Determines bung count and location.
  10. Check the truck for an emissions-era air pump bosses (A.I.R.), which decide Hedman 69110 vs 69111.

Fact-check notes

Checked: Hedman 69110/69111/63820/69820/62826 fitment and specs (search descriptions of CJ Pony pages; the pages themselves 403 on fetch), Hedman mid-length 69170/69176 (Chevy Hardcore article, fetched), Patriot 806-V (search listing), Flowmaster 17742 (Eckler's and JBS fetched; Flowmaster site 403), Pypes SGT978SE (not recheckable), Doug's D303Y (Pertronix, fetched), Hooker 2841 (Billy's, fetched), Speed Engineering 25-1060 (PSI, fetched: LS/LT only), Remflex 2030/2013 (fetched), Borla Touring (Penguin Garage, fetched), Dynomax 17220, Flowmaster 53055, 530552 (JBS, fetched), plus about 15 forum/tech URLs. Roughly 30 URLs touched; 8 returned 403 (CJ Pony, Jegs, Flowmaster, Summit-class blocks, ck5, Bangshift), 1 dead (Engine Labs ?p=301074, 410), 1 404 (an alternate HPA Motorsports Borla page, not cited).

Changed:

  • Flowmaster 17742 price/fit: Eckler's $1,065.95 (out of stock); JBS $1,449.93; flagged as needing header-back fabrication; vendors disagree on crossmember-back vs header-back.
  • Muffler inlet size must match 2.5" pipe; Super 50 530552 is a 1988-93 truck muffler; non-US retailer currency flagged; 53055 now $204.95.
  • Borla Touring part number conflict (401661 vs 401663) flagged; Dynomax 17220 noted as short-body.
  • Hedman 62826 fitment corrected to 68-87 per CJ title; 69110 unreliable $794 price removed; 69111 CARB E.O. and 1975+ legality notes added.
  • Doug's Tri-Y removed from the Better/Best tiers (power through ~4,500 rpm only).
  • Added the missing Hedman mid-length 69170/69176 option for lowered trucks.
  • Corrected the recommendation: the "tucks in the frame" forum evidence applied to car-style headers, not truck tubes; recommendation now depends on ride height.
  • H-pipe vs X-pipe: an earlier pass made the H-pipe the default from one Jalopnik summary; the integration pass fetched Jalopnik and Pypes, found the area is taste-driven, and restored the owner's X-pipe + resonators as the default with the H-pipe as an option. (The 'cited Jalopnik says the reverse' line in the earlier pass was itself muddled; Jalopnik does say H-pipes tame drone.)
  • Primary-size support softened (Century page: 1-5/8" to 1-3/4" for mild 396-454).
  • O2 guidance: Holley says 1-10" past the collector; dead source noted.

Not verified: Patriot 806-V price and fitment reports; Pypes SGT978SE price; Jegs/Summit prices (blocked); Jet-Hot quote; Hooker BlackHeart crossmember claims; any dollar figure for custom exhaust labor.

Sources 52

  1. cjponyparts.com (search result)
  2. cjponyparts.com (search result)
  3. billysspeedshop.com (fetched)
  4. billysspeedshop.com (search result)
  5. cjponyparts.com (search results; page 403 on fetch)
  6. cjponyparts.com (search result)
  7. cjponyparts.com (search result)
  8. cjponyparts.com (search result)
  9. cjponyparts.com (search result)
  10. jegs.com (search result with review)
  11. flowmastermufflers.com (search result)
  12. cjponyparts.com (search result)
  13. cjponyparts.com (search result)
  14. psiconversion.com (fetched)
  15. pertronixbrands.com (fetched)
  16. cjponyparts.com (search result)
  17. speedwaymotors.com (search result)
  18. centuryperformance.com (fetched)
  19. gmsquarebody.com (fetched)
  20. gmsquarebody.com (fetched)
  21. stainlessheaders.com (fetched)
  22. stainlessheaders.com (search result)
  23. forums.corvetteactioncenter.com and grassrootsmotorsports.com (search results)
  24. ecklers.com (fetched)
  25. cjponyparts.com and tahoeyukonforum.com (search results)
  26. jbspowercentre.com (fetched)
  27. fiperformance.com (search result)
  28. jegs.com (search result)
  29. jegs.com (search result)
  30. jegs.com and jegs.com (search results)
  31. penguingarage.com (fetched)
  32. makperformance.com (search result)
  33. ck5.com (search result)
  34. gmsquarebody.com (fetched)
  35. cjponyparts.com (search result)
  36. gmsquarebody.com and search summaries on header/PS-box width (fetched/search)
  37. ebay.com (search result with buyer comments)
  38. gmsquarebody.com (fetched)
  39. enginelabs.com (search result)
  40. gmsquarebody.com (fetched)
  41. gmsquarebody.com (fetched)
  42. gmsquarebody.com (fetched)
  43. gmsquarebody.com (fetched)
  44. gmsquarebody.com (fetched)
  45. performanceonline.com (fetched)
  46. jalopnik.com (search result)
  47. enginelabs.com (search result)
  48. classicmotorsports.com (search result)
  49. knowledgebase.blueprintengines.com (search result)
  50. chevyhardcore.com (fetched; Hedman mid-length 69170/69176)
  51. cjponyparts.com (search result)
  52. 7173mustangs.com and gmsquarebody.com (search results)