496HO Header's

[jrgaudettes]

Looked great, install looks easy. Also good hp increase. Going to talk to JW at Ultra to see if adding these will void my warranty. If not then I will get them, If so I will add after the warranty expires. :D

[KineticoH20]

Replace your exhaust, keep your merc's, if there ever was a warrantee issue just put the merc's back on.;)

[jrgaudettes]

Replace your exhaust, keep your merc's, if there ever was a warrantee issue just put the merc's back on.;)
True....:D

[Beer-30]

Looked great, install looks easy. Also good hp increase. Going to talk to JW at Ultra to see if adding these will void my warranty. If not then I will get them, If so I will add after the warranty expires. :D
Which brand are you referring to?

[ULTRA26 # 1]

Bob,
What were the dyno results on Dana's new 496 exhaust? HP and torque.
Thanks
John M

[Dana Marine Products]

I'll be posting more detailed information on this subject tomorrow. Many of you have probably seen them at the show. We have the new video of the dyno work and boat install playing in our booth as well as Eliminator's. (we used the new 22 Daytona for the install) The boat at the show is the one we ran. I've seen alot of nice comments about the looks of that boat, but let me say first hand, that boat runs awesome. It loves to run fast. That boat right now will cruise at 66 mph at 3500 rpm. And it's smooth as glass. We ran top speed at 83 mph, stock was 77 mph.
I'd also like to publically thank the following people,
Ray and Larry from Raylar Engines, these guys are in it to win it. They donated 4 full days at absolutely no charge to help us get this project off the ground. They also had alot of input on the initial developement of the kit. Top notch people, that are truly into providing high quality products.
John West and Mike Harland from Ultra Custom Boats, these guys let us use three brand new 496 engines for both the dyno work and our display engine that we have at the LA Boat Show. John's always up for cool projects and his generosity allowed us to complete the project on time. Without the engines, we'd still be sitting in square one.
Bob Leach from Eliminator Boats, One of the nicest down to earth guys I've ever met. Bob didn't hesitate for a minute at our request to use his brand new boat. The 22 Daytona was a perfect boat for our water testing.
Paul and Kirk from Extreme Custom Marine, Paul was brave enough to go boating with me in 30 degree weather and wide open throttle. Paul's extensive knowledge of the Mercruiser 496 was very helpful in our completion of this kit. He personally performed the engine diagnostics including portable exhaust temperature readings to insure against any lean conditions. Being within a few minutes of lake Elsinore, Paul ran down to help us out several times. Again, without his help, we'd still be trying to figure things out.
I think it's important for everyone to know that Dana Marine Products received alot of help on this project. We didn't just throw some half ass exhaust kit together. The guys that I mentioned are true professionals and are a huge asset to the marine industry. Thanks again guys!

[Dana Marine Products]

Here's a quick run down,
496 Mag - 423 HP - 534 ft lbs of torque
496 HO - 478 HP - 548 ft lbs of torque
496 with Raylar 525 conversion - 555 HP - 604 ft lbs of torque.
We had huge HP and torque gains. Average torque gains were very impressive. The 496 HO never drops below 500 ft lbs from 2600 rpm to 5000 rpm.
I'll be posting a much more detailed thread within the next day or two. The dyno sheets are available at the show or I'll be happy mail them to any inquiring party.
This is the real deal, no tweaked or stretched numbers.
This is the only TRUE 496 kit that really is simple to install. I did a complete kit on the launch ramp in less than 3 hours.

[ULTRA26 # 1]

Bob,
Those are impressive numbers and ease of the install is also impressive. It sounds to me like the new Dana 496 exhaust system is going to be the 496 system of choice. Similar performace increase, much easier to install and considerablly less expensive than the only other true 496 system available. IMO it's a no brainer. Another job well done.
JM

[Dana Marine Products]

Just to clarify what I mean when I say "TRUE" 496 kit, the new DMP kit is exactly that. When you get this kit in a box it is installable within 3 hours. There is no bracket mods or relocations necessary. The exhaust outlets are positioned to be exactly the same as the stock Merc manifolds. I know there are other 496 exhaust systems out there, just about any BB Chevy manifold or header will bolt onto a 496 engine, but none of them will fit the same as the stock manifolds. Ours do. There's currently no other system that does not require complicated modifications to install. I know there's other systems that will make good HP. But none offer the features that this kit does. That's not even mentioning the cost yet.
It's been a long road traveled to get this exhaust kit dialed in, and I'm proud to say, it's truly unmatched considering HP, and ease of installation.
I'll have the video on my website within a few days.
Thanks for the continued support John, you've always been a good customer. I can't wait to see some in action shots of your new windshields.

[ULTRA26 # 1]

You got a deal
John M

[charlyox]

Can I get a price check on those headers? $$$$$$$$$$$$$$

[Dana Marine Products]

The kit is $2550.00. That applies to all 496 mag's and early model 496 ho's. Late model 496 ho's (idenified by the fuel system being mounted on the starboard side of the engine) requires an adjustable fuel pressure regulator which adds $175.00. A fuel pressure gauge would be needed to install the late model 496 ho kit, they're about $55.00. That's a temperary gauge that installs directly onto the engine.

[THOR]

The kit is $2550.00. That applies to all 496 mag's and early model 496 ho's. Late model 496 ho's (idenified by the fuel system being mounted on the starboard side of the engine) requires an adjustable fuel pressure regulator which adds $175.00. A fuel pressure gauge would be needed to install the late model 496 ho kit, they're about $55.00. That's a temperary gauge that installs directly onto the engine.
Any ides of how much the package is installed on an HO?

[Dana Marine Products]

We don't do installs, but here's a list of guys that can help you with the installation quote,
Extreme Custom Marine - 951-674-9100
B&D Marine - 626-443-3721
GT Performance - 909-982-8391
Prime Marine - 909-484-8338
Concept Marine - 909-447-4411
These are some so cal guys, we also have a Havasu install point if necessary.

[ULTRA26 # 1]

The kit is $2550.00. That applies to all 496 mag's and early model 496 ho's. Late model 496 ho's (idenified by the fuel system being mounted on the starboard side of the engine) requires an adjustable fuel pressure regulator which adds $175.00. A fuel pressure gauge would be needed to install the late model 496 ho kit, they're about $55.00. That's a temperary gauge that installs directly onto the engine.
Bob,
Is the need for an adjustable fuel pressure regulator, on late model HO's, the result of lean condition? Is so, at what rpm range did you discover this to be occurring.
Thanks
John M

[Dana Marine Products]

The lean spot was basically the same on the dyno and the water, in between 3000-3800 rpm it gets pretty lean. I'm not an air flow/fuel flow expert, but the O2 temp readings were 14.01-14.02 in that range. It gets a little better at higher RPM's, but it's still pretty high, 13.8. Both the dyno guy (professional engine builder) and our brothers at ECM felt that was too high for continued usage. Once you factor in ambient air temperature, that # could change. It's one of those things, can you run them without changing the fuel pressure? The answer is yes, but I gotta tell you, it would make me feel pretty uncomfortable if I wasn't strongly urging my customers to make the change. It's such a simple change, It would be foolish not to do it.

[ULTRA26 # 1]

Bob,
Thanks for the info. Something to think about for sure.
JM

[JB in so cal]

So a complete HO kit for less than $2800 total??:idea: :idea: On a boat my size, would a 5 mph gain be too optimistic?

[Dana Marine Products]

Yeah - under 2800.00. 5 mph? I've had guys pickup more, and I've had guys pick up less. I'd say you'd be pretty close with a 28 cat.

[Jesster]

Here's a quick run down,
496 Mag - 423 HP - 534 ft lbs of torque
496 HO - 478 HP - 548 ft lbs of torque
496 with Raylar 525 conversion - 555 HP - 604 ft lbs of torque.
We had huge HP and torque gains. Average torque gains were very impressive. The 496 HO never drops below 500 ft lbs from 2600 rpm to 5000 rpm.
I'll be posting a much more detailed thread within the next day or two. The dyno sheets are available at the show or I'll be happy mail them to any inquiring party.
This is the real deal, no tweaked or stretched numbers.
This is the only TRUE 496 kit that really is simple to install. I did a complete kit on the launch ramp in less than 3 hours.
Any Pre install numbers for the same engines to get a look at what the actuall increases were?

[undertaker]

Just ordered a set from Jaime @ Lakeside Restorations for my Donzi 22 classic with 496 HO along with a set of the new straight cut tips with removable flaps. Come on spring:D :D
Undertaker:D

[Dana Marine Products]

The 496 mag dyo'd right at 380 hp and the 496 HO dyno'd at 433 HP. From what I'm told, it's not uncommon for the engines to be 10-15 HP off from one another. One other engine builder I know recently dyno'd a 496 HO and it made 417 HP. I'm sure that there is a slight variance from dyno to dyno. The dyno that we used is a DTS4000, all numbers are SAE certified.

[Beer-30]

I know Raylar dyno'd an HO at 421 or 422. I was amazed how close it was to the 425 rating.
+/- 10 or 15 is common.

[speedneeder]

Do you have a similar set up for a stock 96 502?

[Beer-30]

Do you have a similar set up for a stock 96 502?
http://www.danamarineproducts.com/ProductDetails.cfm?group_id=10&catid=75&productid=172&CFID=278836&CFTOKEN=41138951

[Dana Marine Products]

We have several riser styles to fit our exhaust. For a 502 with thru transom exhaust (no silent choice or "S" pipes) I would suggest using the Vortex #4 riser and manifold combo. You can expect roughly 38-40 HP increase and 32-35 ft lbs of torque. The weight loss is rouglhy 75 lbs compared to the stock Merc manifolds.

[Hotcobra270]

Here's a quick run down,
496 Mag - 423 HP - 534 ft lbs of torque
496 HO - 478 HP - 548 ft lbs of torque
496 with Raylar 525 conversion - 555 HP - 604 ft lbs of torque.
We had huge HP and torque gains. Average torque gains were very impressive. The 496 HO never drops below 500 ft lbs from 2600 rpm to 5000 rpm.
I'll be posting a much more detailed thread within the next day or two. The dyno sheets are available at the show or I'll be happy mail them to any inquiring party.
This is the real deal, no tweaked or stretched numbers.
This is the only TRUE 496 kit that really is simple to install. I did a complete kit on the launch ramp in less than 3 hours.
very interested in this kit.. Is the video up and running on the dana website?
Also, where can I get info on the raylar 525 convertion? Can you give us some info on it?
thanks

[Beer-30]

very interested in this kit.. Is the video up and running on the dana website?
Also, where can I get info on the raylar 525 convertion? Can you give us some info on it?
thanks
http://www.raylarengine.com/
Also, search on here on Raylar, you will get a bunch of info.

[Dana Marine Products]

The Raylar kit consists of new aluminum heads, a new camshaft, and intake manifold. I watched them install one on the dyno, the kit went together very smoothly. With the kit installed with the Dana Marine exhaust the engine made over 560 HP and 604 ft lbs of torque. The torque level never dropped below 500 ft lbs, most of the time it was well over 550 ft lbs. (3200 rpm-5300 rpm's)

[Dana Marine Products]

Here's a link to the dyno sheets,
http://danamarineproducts.com/installation/DynoFlyer_HighRes.pdf

[undertaker]

Here is my new exhaust just installed:D :D

[undertaker]

One more:D :D :D

[Decided Advantage]

Some good work was done over at Full Throttle Marine on this subject. I'd love to see the CMIs in this comparision.
http://www.fullthrottlemarine.com/
The Dana exhaust looks like a product that could be installed and forgotten. my experience with tube headers says you install an area of consistent maintenance. Is this consistent with others experience?
So would a set of black power coated Danas go down as "stock replacements"? Exhaust mods are on the long list of No-Nos from my insurance company. I don't see the Danas being responsible for sinking the baot which has happened more than a few times with failed tub headers

[Sotally Tober]

Here is my new exhaust just installed:D :D
Those are gorgeaus!
Wonder if they would help my HO.

[undertaker]

If no performance gains at least you have the bling and better sounding exhaust:D :D :D

[westair]

If no performance gains at least you have the bling and better sounding exhaust:D :D :D
Did you see any performance gains? I am hoping to move up
one prop size 24P to a 26P if I install them.

[Dana Marine Products]

Every application we've done has needed a 2 pitch increase. The only time you would not need to increase the prop size is if the boat is already over propped. If your turning 4800 rpm or less, you probably won't need to change props. If you're already spinning 4900-5000 rpms, you'll have to prop up.

[undertaker]

Did you see any performance gains? I am hoping to move up
one prop size 24P to a 26P if I install them.
I need to re prop I was turning 4800 RPM with factory exhaust 25P prop, now I am hard on the rev limiter at 5000 RPM going to try a 26P prop and see where I am at not sure I can turn a 27P.... will keep ya posted on performance with new prop...
Undertaker

[Petesflht]

hey Bob; ordered your EX 2000 polished set today trough Marine Toys in Vancouver Canada. 30+ days to get them to Canada, can ya help BUD??

[Dana Marine Products]

We'll see what we can do. We are shipping systems out, but we are filling current back orders. I don't know if there's a whole lot we can do, just becasue the curretn back log is pretty large.

[undertaker]

Did test again with the 26P prop still on the rev limiter not as hard but on it saw 75 MPH with three people and full of fuel...guess I should have listened to Dana & Jaime @ Lakeside Restorations who did the install he said I would need a 27P.......soooo I am getting a 27 and will be retesting later this week. I hope to see a solid 3-4 mph increase, we shall see when new prop arrives.....:D :D
By the way I do like the exhaust they sound great and gave me more mid range...:D :D :D

[undertaker]

Could not turn the 27P lost my acceleration and RPMS going back to the 26P and getting some senor issues resolved this week...will keep ya posted once I can run the boat hard enough without the warning buzzer going off....
Undertaker:D :D

[Dana Marine Products]

Hey Under, after more discussion with some Merc guys around here, it sounds like you may have a bad exhaust temp sensor. I guess they're very sensitive and go bad quite often.
As stated on OSO, once you get the sensor issue resolved, you'll probably get different results from the 27 pitch prop.
We just did an install Monday over at Eliminator on another brand new 22 Daytona with a 496HO. Running a 28 pitch 4 blade Bravo prop we were at 5100 RPM 81 MPH, with a 30 pitch 4 blade Bravo prop we were at 4700 rpm 82 MPH, and with a 30 pitch labbed finish prop we were at 5000 RPM 85 MPH. The installation took an Eliminator rigger 2 hours, and everything worked perfectly.
They were very suprised at the ease of installation and the results.
I've also recently spoken to one of our distributors who have done over 6 installs within the last 3 weeks, and they have had excellent results. Not only from the ease of installation, but every boat has been ran before exhaust upgrade and after, every boat has ran flawless, with no issues at all. Every boat has picked up a minimum of 4 MPH.
If possible, PM me your phone number, I'd like to go over some things with you.

[ULTRA26 # 1]

Could not turn the 27P lost my acceleration and RPMS going back to the 26P and getting some senor issues resolved this week...will keep ya posted once I can run the boat hard enough without the warning buzzer going off....
Undertaker:D :D
I have run across many props that don't act like thier advertised pitch. You may want to have the 27 checked for excessive pitch and/or cup. Just my
.02
John M

[undertaker]

I have run across many props that don't act like thier advertised pitch. You may want to have the 27 checked for excessive pitch and/or cup. Just my
.02
John M
Thanks for the info....I will check it out...

[undertaker]

Hey Under, after more discussion with some Merc guys around here, it sounds like you may have a bad exhaust temp sensor. I guess they're very sensitive and go bad quite often.
As stated on OSO, once you get the sensor issue resolved, you'll probably get different results from the 27 pitch prop.
We just did an install Monday over at Eliminator on another brand new 22 Daytona with a 496HO. Running a 28 pitch 4 blade Bravo prop we were at 5100 RPM 81 MPH, with a 30 pitch 4 blade Bravo prop we were at 4700 rpm 82 MPH, and with a 30 pitch labbed finish prop we were at 5000 RPM 85 MPH. The installation took an Eliminator rigger 2 hours, and everything worked perfectly.
They were very suprised at the ease of installation and the results.
I've also recently spoken to one of our distributors who have done over 6 installs within the last 3 weeks, and they have had excellent results. Not only from the ease of installation, but every boat has been ran before exhaust upgrade and after, every boat has ran flawless, with no issues at all. Every boat has picked up a minimum of 4 MPH.
If possible, PM me your phone number, I'd like to go over some things with you.
Dana you have a PM...

[OC28HEAT]

Ordered the Dana exhaust on 5-25 I have an appointment to have the exhaust and some Dana Tabs insttalled on 6-13
do you think that I can pick it up before then

[Petesflht]

recieved my kit today, talk about bling, sure is sweet looking stuff Bob. Should get installed tomorrow, will keep ya posted on performance increases.

[ULTRA26 # 1]

recieved my kit today, talk about bling, sure is sweet looking stuff Bob. Should get installed tomorrow, will keep ya posted on performance increases.
You're going to love your new found performance
John M

[undertaker]

Could not turn the 27P lost my acceleration and RPMS going back to the 26P and getting some senor issues resolved this week...will keep ya posted once I can run the boat hard enough without the warning buzzer going off....
Undertaker:D :D
Well got my boat back... finally got my temp sensor problem fixed (was NOT a bad temp. sensor), going out today to retest my props since now I will be able to actually run my boat without buzzers going off.....we keep ya posted on results:D
Undertaker

[undertaker]

Retested the 27P TXP NO GOOD staying with the 26P TXP running 4900 RPMS @ 75 MPH (GPS) going to try some four blades and see if I can sweak out maybe 2 more mph we shall see..
Exhaust install once I worked out the gremlins gave me 2-3 mph at this point maybe 4 mph if I can get the perfect prop and noticable mid range torque boat pulls real hard to 4900 now:D :D....and of course more bling and better sound:D :D :D :D
Undertaker:D

[undertaker]

Not to give Dana a hard time, because I love my new exhaust....but there are three cases that I know of so far that have had the same heat sensor issue that I have had, I fixed my issue, if you run into the same problem with your new exhaust shoot me a PM I would be glad to throw you a bone with this issue..:D :D :D
Again I hope Dana does not get offended with my post just trying to keep others from going through what I did to fix the problem....
Undertaker:D

[Dana Marine Products]

Hey Undertaker, no sweat. The bottom line is, stuff happens. No matter what is built, there's always going to be some sort of issue. I'm just glad you got it figured out and that you're happy with the product and the results.
As for the problem, We have had two cases (that I'm aware of) where there was a heat issue with the port side manifold. The problem seems to be with the lower drainback fitting. These fittings are the stock Merc lower fittings that are re-installed into our manifolds. These drainback style fittings allow for the exhaust water to be drained during cold storage. Unfortunately they seem to stick open in rare cases. Once stuck open, 50 percent of the manifold water is bypassing the manifold, thus the manifold heat problem. This scenario is pretty rare, 98 percent of our installations work with no problem. The reason we kept this stock system compared to plugging them off is to retain the stock drainback system.
Both of the known heating problems have been solved by plugging off the drainback lines, thus forcing all of the water through the manifolds. (just as every 454 and 502 have ever been) This drainback system is only applicable to 496 applications.
We don't feel that it is a necessity to plug off these drain back lines. I'm currently looking at this fitting a little closer to find out why it would possibly be bypassing. I'll keep an update on this situation.