It's amazing what a little fine-tuning and quality parts will do. We've been subjecting this '72 Chevy C-10, which is by no means above average, to anything you could find across the country in local classifieds. One of the worst things about the truck's mechanical state was the exhaust system, or what was left of it. At one time someone put in full-length headers, glasspacks, and an H-pipe to make up what might have been a decent way to flow the exhaust out of the engine, but--it's always the but--the original parts used were pretty cheap. This translates into a few years and miles down the road and the thin-wall rusty tubes are looking more like Swiss cheese than headers, not to mention attaining the neighborhood nuisance badge for the ruckus the truck made.
Enough was enough. Who do you go to for a set of headers that actually work and are made to last? How 'bout a company that's been proven since 1959 and copied and imitated due to their outstanding reputation--Doug's Headers. The original Doug's Headers is still huge in the performance headers business. It's the only company that still has the same Doug from 47 years ago on the payroll for design and consulting, not to mention all his previous production designs. They happened to have a set of Tri-Y full-length headers (PN#D372Y) that would slide right between the afflicted Bow Tie's fenderwells. These new breathing tubes are substantial; it was almost a shame to hide 'em under a hood! They have 3/8-inch flanges and consist of properly routed 16-gauge tubes coated in silver Metallic Ceramic Thermal Barrier Coating, which as far as Doug's is concerned is the best header finish on the market. The MCTBC protects and extends the headers' life significantly and looks fantastic.
With the confusion of finding a set of headers out of the way, we needed something to pick up where Doug's left off. Most would probably cart the truck down to the local muffler shop to get some lengths of galvanized tube bent up and consider it good. Well, that's what happened with this truck before, and we can all see how well that lasted. Doesn't everyone have a million bucks to get a complete custom stainless system made and a week of downtime to get it done? Fear not! MagnaFlow just introduced a "crossmember-back" stainless steel dual-exhaust kit complete with 2 1/2-inch mandrel-bent tubing, a MagnaFlow Tru-X crossover scavenger pipe, and polished dual stainless steel mufflers, hangers, and heavy-duty clamps. Crossmember-back means it'll match up to most existing/new headers or exhaust manifolds and completes the system from the tranny crossmember-back. This kit was engineered and designed from a '67-72 Chevy longbed, but is easily abbreviated for a short-wide by shortening the inlet tubes that reach the headers.
I took the C-10 test mule down to MagnaFlow in Rancho Santa Margarita, California, to have the pros who whipped up this kit show us how easy it really is to install, and even though this is the second shortbed to receive it, it's definitely ready to ship and not a prototype. MagnaFlow advises customers to take their truck to one of their recommended muffler shops/distributors for an even quicker and painless job that should only take a couple of hours. Even though only a few cuts are needed, all it takes is one too many or the old "I cut it twice and it's still too short" scenario to botch the job.
After a quick stint on MagnaFlow's lift, this Doug's Headers/MagnaFlow system gained 17 hp and 46 lb-ft of torque over the old ratty custom setup in the truck--that's a power gain you can feel on the street. Now, the old grey mare chirps second! One hundred thirteen horsepower and 221 lb-ft of torque might sound pathetic, but this is the real world, and at least the numbers are going up.

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 MagnaFlow is perpetuating...  MagnaFlow is perpetuating the C-10's popularity by offering this complete stainless steel exhaust "crossmember-back" kit, which consists of 2 1/2-inch mandrel-bent tubing, a MagnaFlow Tru-X crossover scavenger pipe, polished dual stainless steel mufflers, all the necessary hardware, and a lifetime warranty! |
 I'd bet most everyone has...  I'd bet most everyone has at least heard about Doug's Headers over the years--remember the name in gold leaf stretched across the front fenders of the legendary Chevy 2 Much? The same Doug's Headers from 1959 brings us these oval-port Tri-Y headers for the '72 C-10 we've been working on getting up to snuff. After concluding that the Metallic Ceramic Thermal Barrier Coating (MCTBC) was the best header finish, Doug's decided to make it standard on all their headers to eliminate any corrosion or protection issues down the line. The best deserves the best. |
 Last month I mentioned that...  Last month I mentioned that our fresh-out-of-the-classifieds C-10 needed some help in, well, just about everywhere. The Chevy still got us around town, much to the dismay of those in both eye and earshot. Knowing there was a significant exhaust leak before the truck went on the lift wound up being a laughable yet disturbing header repair job. |
 The patchwork on the old crusty...  The patchwork on the old crusty headers consisted of a parts store patch kit, Diet Coke cans, and lots of copper wire. The rest of the exhaust was close behind in appearance, so I cut everything out with the Sawzall up to the collectors at the headers so they could come out, as well. |
 To drop the old headers out...  To drop the old headers out from underneath, the spark plugs had to come out--marking the wire for #1--and the temp sending unit wire was disconnected. |
 With the truck up in the air...  With the truck up in the air and the truck gods smiling down on me, the old header bolts came out too easily and quickly, allowing the removal of the last of the rusty tubes. If your truck has some scary-looking bolts holding the manifolds or headers in, get out the penetrating fluid and use it to your advantage. |
 One of the things that elevate...  One of the things that elevate the original Doug's Headers over the competition is that they use 3/8-inch flanges standard and even thicker ones on heavy-duty applications. Performance engines can produce super-heated conditions that will easily warp thinner flanges, causing all kinds of problems, including exhaust leaks. Note the "DOUG'S" badge on the front tube--that's how you know they're the real deal. |
 Trying not to bump my head...  Trying not to bump my head on the grease-caked undercarriage, I slipped the new Doug's headers up into place and threaded in one header bolt to hold it in place while I handled the other side and lowered the truck down. |
 Make sure to install the new...  Make sure to install the new header bolts with their lock washers to help keep 'em where they need to be. Start with the outside two on each header to help with gasket installation. |
 With a small amount of hi-temp...  With a small amount of hi-temp silicone around each port on both sides of the gaskets for extra insurance, they went in... |
 ...and all the header bolts...  ...and all the header bolts were tightened down to around 35 lb-ft. |