Thanks Phil...I'm still concerned about the proximity of the O2 sensor's wiring being so close to the heat shield even after I pounded it back (1/4" clearance from end of sensor to shield)...I'm going to remove the header and weld in another bung in a better location if that's possible...there's no slack in the O2 sensor's cable...

How did you handle the heat shield issue? Are you using the O2 simulator?

Just got back from a long test drive in the rain...yes, it was for a good cause and she's all washed up and dried...My impression now is that I'm becoming addicted to the new music...it's the same as when I had the Milteck and my modified Borla only when I get on it, it will rival most Harleys...mostly at the rear

Because of my megaphone like extended tips, the sound is far enough back that I know it's loud but it's projected back and doesn't intrude too much into the cabin (It's apparent when I pass an oncoming car and the sound bounces off their side)...Even at WOT with driver's window open about 4 inches, I can still carry on a conversation without shouting so my wife shouldn't object...

One thing for sure, the Canadians are really going to hear me coming from the American side of the tunnel

 

LMAO

 

So glad you like the sound, Sid! I always had a minor drone from my Milltek, even with the stock header, which was exacerbated with the Megan. Not bad, but a little annoying over long periods in the countryside. I fixed it with some acoustic material left over from my stereophile days, and the installation of a new the back shelf to replace the one I had inadvertently left in Las Vegas (some things *do* stay in Las Vegas, damn it!)
Anyway, to your questions: Yes, the pre-cat o2 sensor is in a very bad location, and I ended up doing some pretty serious cutting and molding to get the wires to locate between the shift cables, while keeping the heat shielding on those items. It's all good now, and I managed to get enought length so that the wire is not at all under stress, and shielded from heat.
I do run a simulator, and it's spliced into the post-cat sensor, with no problems at all, installed as per the o2simulator instructions. (I love how the simulator has the MINI logo stenciled on to it--looks like an OEM part!)

Anyway, all's well that ends well. Enjoy the sounds...

 

Good to hear...I think this story will end up as another success

 

Any issues with fitment on the "megan" header? Issues with bolts at the head, the fake cat, anything?

I may consider this route, but would want to make a jig and replace the test pipe with a real cat. I won't be able to leave the car on stands for a few days, it all needs to bolt in in one shot!

thanks!

-jac

 

It's not a fake cat, it's a resonator. It's actually a plus since it means you can get lots of pieces fabricated to fit in the space between the header and the catback. I have the resonator, a race pipe and a Magnaflow cat. Changing is a simple lift of the car, remove the o2sensor and 4 bolts, swap and reverse steps.

 

Okay this post is very predictable...

Are there any flames?

Sorry... I had to ask lol

Mikey

 

Sorry Mikey...won't know until I get her out...at night...it's been pouring ***** around here and the last thing I need is to be caught in the dark rainy night while my exhaust is yelling at the cops "HERE I AM...CATCH ME!!!"

Sides...I can't get any traction in this weather so it's hard to open her up....And if there were flames...that would just nail my coffin...cop at court, "Your honor, the defendent was caught while exceeding twice the speed limit with a very loud exhaust and flames coming out the rear"...me, "I can explain that your honor...but I'll take the 5th..." lol:

 

hey that situation feels familiar... oooops you didn't hear that. Yeah I gotcha it's cool. I already get enough attention with a straight exhaust as it is, but of course I want more speed, so attention will come with that. Yeah but two flames coming out of my car would be almost like the batmobile that's pretty sick.

Mikey

 

You to eh? I believe I can relate completly! Out in the open cruising along its almost quiet. But step into it through a section of town where you're in a "canyon" of paralel storefronts or a tunnel & OMFG

 

 

you are bad to the bone my friend..... I know how loud that is....... so tell me, the port matched Megan feels good....... told you

 

We all answer to a higher authority

 

One year older and I have a headache...where's my cake?

Oh now that I have Msfitoy up on jacks...it's gorgeous out side...:impatient

 

It's your bday? If so, happy bday!

Why is msfitoy up on jacks?? Get it down from there and go enjoy that exhaust!

 

Thanks...Still need to get under and trim the heat shield to clear the sensor...I'm also painting my plate before using the tab...Have to get this done as my license has expired

 

Well...here's my blog for the day...

While everyone was asleep last night, I was out in the garage listening to loud tracks that I downloaded into my Ipod and lost track of my beverage count while counting down to my 48th...obviously, my math needed help but I did have fun while it lasted

This morning, I paid for it... But I had a mission to accomplish...my plate expires today and I didn't want to use the tab until I customised the plate with textured black paint...this required the patience of a brain surgeon but it had to be done today or I can't take Msfitoy out...I laided blue painters tape over the letterings and trimmed each every single letter I then shot the plate with two coats of flat black followed by two coats of textured black which gave it a textured semi-gloss look...Came out great but it looks blue in the picture due to the reflection of the sky from the clear plate cover...



I removed all three O2 sensors and applied anti-sieze which I didn't get to during the last test launch...The heat shield was removed, trimmed to clear the O2 sensors and reinstalled...Plugs checked, perfect...O2 sim installed and works as advertised...Cleaned the suspensions/brakes and hung the cleaned wheels...torqued them down...

Sun sets at 5:27...mission accomplished 4:15...time to roll...

 

It will take a few key cycles to see if the ecu throws any codes with the o2 sim. Let me know if you get yours to work a few hundred miles down the road. I have one and I still throw codes.

 

When I had the bad cat, the codes would come every other cycle like clock work...I went through four cycles today and still no code...so far so good...

When I first fired her up, the Mini started to smoke up under the hood and I thought WTF I quickly shut her down and thought the O2 sim was on fire or something but the smoke didn't smell like electrical...soon I figured out that it was the excessive anti-seize application that was burning off...whew!

 

And you said "no flames."

 

Not yet I might go out into the boonies tonight and check for flashes in my rearview...hopefully not the red and blue type

 

Well...the verdict is in...the Mrs tells me that it was loud enough as it was and that she could hear me coming home a mile away...now, she can hear me two miles away...The bad news is that she's right...I can't get on it without bringing attention to at least two precinct of police and she doesn't think she can handle the "music" all the way to the Dragon...Too bad for me because I LIKED IT!...but it is kinda like bringing a sledge hammer to a china party...especially when I'm in the city where the "music" echos loudly off every single building...If I hadn't modified my Borla Race, it would've been just right...

So here's the story...I have someone in line for the header but if that falls through...PM me if you're interested...

The header is not labeled Megan but is manufactured by the same company and distributed by Edge...it is identical to the Megan...

I'm selling the header/test pipe, flange ported to match the Webb head (which is identical in size to the OEM header gasket BTW...also, it will work just find with a standard head), a third bung welded in for any wideband AF sensor...and a small 1/4" hole drilled for EGT probe (you can have this welded shut if you don't need it)...less than 100 miles...asking $180 plus shipping...

I also have the heat shield trimmed and flanged to clear the unique O2 sensor location on this header which requires slight modification of one heat shield...if you send me your unmodified heat shield, I'll send you mine...

Now, for the rest of the story...my Optima died so I got it replaced under warranty...I ported the Miltek header and mounted it on last night...still sounds purrty as it did before...just not as brash as the "other" header

While I had the parts off, I painted the heat shield with high temp ceramic in whatelse? RED



Oh yeah...everytime I saw a cop in my rearview mirror...I turn off into a parkinig lot Thanks for gettin me all paranoid about my plate...:impatient

 

Why don't you try a high flow CAT before selling. I mean you already have all the effort into the port matching. You know your going to do it all over again with whatever you put on there.

 

I already have a high flow cat...it's part of the Miltek header...the Miltek is also ported...

 

did u find that the miltek header required alot of porting to match the cylinder head? ..

also - not sure if u already answered this, but im assuming u used the stock header gasket as a 'template' to see how much needed to be cleared - is this correct?