Well, after doing quite a bit of reading in the various header threads, I am not really sure which way I want to lean now on my exhaust upgrades for the little V10. I already know I have a couple exhaust manifold studs broken, so it seems that it is time to start looking in the direction of repairs.
It seemed that many people were still having problems with the Hedmans joint deforming, even after Hedman supposedly fixed the problem. Even though the price on them is great, and this was several years ago, I just don't trust that the problem was sufficiently fixed.
This is making me lean towards either the Thorleys, or the Banks. I was just curious what you guys thought about them, which is better, type of thing. Maybe one has thicker flanges and tubing than the other? Warranty comparison? Or maybe you guys know of some other sweet headers I don't... I would just like to know what you guys thoughts were on the headers available.


As always, I appreciate your input.

 

I bought the Banks headers for my V-10 (on sale from AutoAnything.com for $850-ish) and was impressed by their quality when I got my hands on them. I have had issues in the past with various other make headers on other vehicles and these have now been on my EX longer than some of those old ones lasted and are still looking good and have been trouble free!
The Thorleys are a nice design and are well made but I went with Banks (also nice design and well made) mainly due to the Bank being made from stainless steel. The Thorleys are not stainless and will require some periodic cleaning and painting to ensure a long service life. I had originally looked at the Headmans too but then read about the ball and socket problems, it does sound like the problems are continuing even after the redesign.
The Banks kit came complete with all needed hardware, Y pipe and several heat shields. I added some additional insulation in a couple of spots mostly because I had it on hand in the garage and I like to waste time on details like that.
With the rest of my exhaust still stock I noticed a seat of the pants performance increase across the entire RPM range, nothing earth shattering, but definitely more GO at all throttle positions. Hardly any change in the exhaust sound and no drone at all, from the driver's seat you can hear some additional flow noise from the headers, kind of like hissing snakes, but it's not loud or unpleasant.
I did a photo write up here of my installation, https://www.ford-trucks.com/forums/1...ll-w-pics.html. And Christina has another here https://www.ford-trucks.com/forums/1...r-dummies.html. A lot of good install info in those threads, hardest part of the job for me was dealing with the tight access and my fat hands.

 

I really need to pull the trigger on a set of those Banks. I have header envy!

 

+1 on the Banks headers. We had a set on our V10 powered motor home, and they were great. Nice power boost, and the sound at full throttle was great. Probably would have increased our mileage, but I was always into the gas to hear the sound! M


Curt

 

I like the fact that the banks are stainless, also the flange is 1/4" thicker, according to what I have read. I am sure they are both very well made. I am just not sure if it's worth twice the price to go with the Banks... I will keep an eye open hoping for them to go on sale for a while, haha. Thorley says they have a lifetime warranty, compared to banks 5 year, just not sure what they are calling a lifetime warranty...

 

I'm for the Banks system also... I had it done on my previous EX, loved everything about it.

 

Don't do the Headmans unless you are ready to fix issues, or put another set on I. A yr or two. I have a replacement set in the garage waiting install.

 

I've been speaking with the guys at Banks for a couple weeks now and finely ordered the powerpack kit with automind programmer. They said to get the most out of the kit, it's best to get the programmer to adjust the motor and trans to take advantage of improved air flow. You can also adjust your speedo for larger tires and clear codes with the programmer. Mine should be in by the end of the month.

 

I have no personal experience with their programmer but have read a few reports from owner who were less than impressed with it. I have been very happy with my SCTtuner and custom tunes from 5StarTuning, when you order from them they have you fill out a calibration request sheet that outlines all mods done to your rig as well as any special issues you are looking to work out. They then take these items into consideration when writing the tunes for your rig. Their tunes are also well known for the excellent trans improvements they offer. And their customer service is about the best you will find.
I don't have a stake in this either way, just passing on some info that I have read and my own personal experiences, good luck with whichever way you go!

 

We went with the Banks Power Pack without the programmer. No problems at all. I eventually want a programmer from 5star. Other than the studs, the worst part was figuring out how to put the drivers side heat shield on. Read the threads WE3ZS posted links to. I did a thread on my install also, and there are a few more pics of the heat shield in it that might be helpful. Sorry I don't know how to link to it. Tom and Christina's threads were really helpful doing mine. I had the laptop in the shop.

 

Tom, that is explains the sound difference perfectly! At first I was a little worried because it sounded different. I do notice a bit more power, but the thing I like the most is the throttle response. I gained a little more fuel economy too.

I had to add my tid-bit to this thread

 

My Ex came with Gibson headers installed by the P.O.

They seem to be a good design and well made, YMMV, but, I've not heard of any complaints about the Gibsons.

 

Does the Gibson headers still use the factory Y pipe?

 

Yes, the factory y-pipe was still on my Ex until two weeks ago when I upgraded the rest of the exhaust system.