Progress on my M2 Downpipe install and a question...
 

Well, I started the installation today. I removed some intake hoses and the ABS heat shield. Then I used a little PB blaster on the 2 bolts holding the pre-cat's heat shield in place, and I took them off with ease just a few minutes later. I had to use a 10mm monkey wrench to remove the lower bolt from under the car since I couldn't fit a socket wrench w/ bit in that tiny space. I then removed the heat shield, which was surprisingly the trickiest part so far.

I had to bend the shield out of shape a bit to get it to slide out. My question is, is it a good idea for me to reshape and reinstall that heat shield when the downpipe goes in? Or is it not necessary? I know that the ABS shield is essential but what about this one?

Thanks again!

it honestly can't hurt. wrap the downpipe if you like while its out of the car. helps keep things cool underhood and its only a few $$

No, the heatshield that went on the precat cant even go onto aftermarket downpipes as theres no way to bolt it down. The main reason it was on there wasbecause there was a small cat convert in the downpipe that would of course, heat up. The downpipe doesnt heat up to much, so the heatshield isnt that important.

If you want to have some sort of heathshield, just use some sort of header wrap on downpipe.

i don't know if u can replace the heat shield because it was originally connected to the precat, there aren't any holes for the heat shield on the m2 dp...i think anyways

D'oh! You guys are right.

I was so happy that I got it off with no problems, that I just started merrily spraying PB blaster on the precat bolts without giving a thought to what the shield had been connected to! :D

Thanks again. I will add the heatshield to my "Museum of Stock". :)

can you buy header wrap at any auto parts store?

Well, I finished the installation!

It went pretty smoothly. All the bolts came off with no problem. For the record, 2 turbo manifold studs came off and the nuts came off the other 2 instead. Kind of an interesting diagonal with the 2 remaining studs. We got the pre-cat out pretty quickly, but to get the downpipe in, we had to remove the shield covering the tranny -- this gave us the right leverage/space with the back of the pipe to get the head over the bolts.

Had to move the top of the pipe around a bit to get the studs that came out back in. ALL of the studs, bolts, nuts, etc. were in excellent condition. I was almost tempted to re-use the gaskets because even they were in good condition, but since I bought both new ones I went ahead and used them. Thanks for the advice to everyone who replied to that other thread of mine about the gaskets! :)

All in all, the M2 downpipe is a PERFECT fit. It was about 1 or 2 inches shorter in overall length than the pre-cat, but upon installation everything connected perfectly. As everyone says, it is AMAZING how much lighter the DP is than the pre-cat. In fact, that pre-cat reminds me of something, a musical instrument perhaps... It kinda looks like a f'ed up Saxophone! :p:

If anyone has any questions about the install, feel free to ask while this is still fresh in my head. I had alot of fun doing it, and the sense of accomplishment doing the work yourself is incredible (this is my first time really working on a vehicle). I look forward to the project value that future mods will bring. Plus, have to give props to my old man, he helped with this installation and with his ideas and knowledge it went very smooth.

Glad that the RX7Club is out here. You guys are great and I couldn't have done it without your suggestions and help! Have a :beer: on me. It's party time!!

Thanks guys.

i did one last week and the top back stud gave me problems, tried everything. 2 hours later it came out and broke the turbo. o well i put a brand new jspec turbo assembly on it runs great now.

Ed, did you end up wrapping the downpipe?

mike

do you have any pics from your install?

congrats on the install. now you need to start looking at ecu options.

Cool, thanx. Just paypal me the $5.00 for the six-pack of Sierra Nevada I had on your behalf... j/k :D .

Congrats on the successful install. However, you have now entered the "FD Vortex", that continuing urge to modify that will end up spinning you and your wallet into the ground if you're not careful...

Hahahaha, Kento is right on the money.

I picked up a used Bonez dp and the bracket was damaged and will easily snap off. I'm wondering if it is even necessary or if I should get it welded. On one hand, the dp is so much lighter than the stock precat that it may not need the support. But, every little bit of support is a good thing. Does your dp have a bracket near the rear flange?

Damn! I had never heard of that happening before. Are you talking about the center section that is B/W the 2 turbos? I wish I knew that happened to you. I have a spare center section that I could have sold you for you a reasonable price.

:doh: Forgot to check back here....

Thanks for the replies guys,

Mike - No, I didn't wrap it, although I am under the impression that I could wrap it without removing it, so I might consider doing it while she sleeps during the winter.

SNracing - I wish I did but I don't have a digital camera. Dang I have to get me one of those. It would make things so much more fun!

Beer, purchase, mmmmm LOL!!! :)

roadster - No, the M2 downpipe didn't come with a bracket and the stock one from the pre-cat is too small. But it fit perfectly with the main cat and it is a SOLID connection. No movement at all, no rattling. and the cat stayed pretty much in place without anything connected to it so I think you will be fine, for at least a little while. I might fabricate a hangar though just for the extra support.

Oh yeah, and it is DEFINATELY time to save for a new ECU (prolly the PFC). I can't really do anything more without it.

Thanks again guys!

How much was the new downpipe gasket and where did you get it? Thanks

I ordered both gaskets from rx7.com. DP to cat was $7.50 and the other was $45.60.

Congrats on the install. The downpipe was the first real thing I did on my 7 too, and it does feel like quite an accomplishment.

Any boost spiking with the new, more open exhaust?

what else is needed for a dp install? i saw that you mentioned the dp to cat gasket, what about the studs that are famous for breaking? also were can i find the studs and other bolts?

Has anyone actually had problems removing the bolts? I had mine DP installed at KD Rotary and at first, I thought "I should just do this myself... it doesn't seem like it would be that hard." But then Dave (fm. KD Rotary) had a heck of a time with the bolts.... he said he couldn't get them loose and broke a few sawzall blades on them... in the end, he said he had to use a blow torch on them... it took him 4 hours!

Most of the time the studs don't break, and the nuts and studs are re-usable. Basically all you need is the dp, dp to turbo gasket, dp to cat gasket, and a new o2 sensor if you want to.

lol, took me 8 hours! Those studs and nuts have been on there for 10 years, and DO NOT want to come off. But soak them long enough and fight them, they'll come eventually. Long story short, I had tons of trouble.

"All the bolts came off with no problem. For the record, 2 turbo manifold studs came off and the nuts came off the other 2 instead. Kind of an interesting diagonal with the 2 remaining studs."




Ed, while it's fresh still....Plan to do my DP fairly soon as well but after I get it to Jet-Hot for a coating. Exactly how many bolts need to be removed once you've taken the two heat shields off?
It was my thinking that there are 4 holding the precat into the turbo manifold?
Are you running a straight pipe cat and DP on a stock ECU? I thought that was a no-no?:)
Congrats!

911GT2 - Unfortunately, my baby's sleeping for the winter as well.. :( So I haven't had a chance to drive her yet. Heck, it'll be like a whole new car come springtime for the first drive, DP, new fuel filter, I'll be putting new S03's on (only driven her on the near-bald tires that came with when I bought her in Sept.), should be interesting! :D

SNRacing - Not sure where to pick up new studs/bolts, but I believe some of the downpipes come with replacement ones. The M2 did not, but all of my bolts and studs were in great condition. Just use LOTS of PB Blaster on them to loosen them up, like give it a 24 hour period with multiple applications of Blaster. Then try removing the bolts. You can do the heat shields without letting it sit that long unless they have rust as well.

Senna - Yep, 4 bolts holding the pre-cat to the manifold, 2 bolts holding the pre-cat to the main-cat. Also there is a bolt on the hangar right before the main cat on the pre-cat. Look/feel up on the top of the precat. I forgot to PB Blast this bolt overnight but it came of with no problem. As for the straight-pipe, that's where some get confused. :) It's a catback without a muffler, not a mid-pipe. The guy I bought my 7 from had it fabricated and put on. I still have the stock cat and will upgrade to a hi-flow cat eventually, but I'll always keep a cat on there.