Sanderson Zoomie Baffle Installation

Sanderson Zoomie Baffle Installation

BAFFLE INSTALLATION PROCEDURE:

First, make sure you have the correct-sized baffle inserts for your application. Baffle selection is based on the pipe's outside diameter (OD). Sanderson baffles are slightly smaller in diameter than the tubes' inside diameter and are manufactured for a 16-gauge tube thickness. Headers with a 1.875" (1-7/8") primary tube OD are used on the majority of engine applications and require baffles with a ~1.750" (1-3/4") OD. Headers with a 2.250" (2-1/4") primary tube diameter are for big-block Chevrolet engine applications and use baffles with an OD of ~2.125" (2-1/8").

Warning
WARNING: A baffle or fastener that comes loose or falls off the vehicle could cause serious injury, property damage, or loss of life. If the mounting fastener breaks or comes loose, the lock nut or washer could get sucked into the engine past the exhaust valve, causing catastrophic damage to the engine.
  1. Please take the time to ensure the baffles are properly installed and secured.
  2. Periodically inspect the installation as part of general vehicle maintenance to prevent a catastrophe

For NEW installations:

  1. Measure Before Installing. Always measure the diameter and total length of the baffle insert. Use the length measurement to mark the outside of the header tube to maintain the proper installed depth.
  2. Notice that one end of the Sanderson muffler insert is partly closed off with a welded washer. Insert the closed end into the header tube.
  3. Position the baffle down the tube. The bottom of the baffle must remain above the lower bend of the Zoomie pipe. Forcing it to bottom out can restrict exhaust flow and may cause engine damage. The correct depth is often slightly below the end of the tube.

  4. Use a small wooden wedge or a compatible alternative to hold the baffle in place while drilling. Place the wedge at the top to force it toward the tube's bottom radius. If the baffle moves around too much, use two wedges, and place them at the 10- and 2-o'clock positions.
    Zoomie Baffle installation Tip
  5. Drill a 1/4" diameter hole through the bottom of the header pipe and through only one side of the muffler wall.
  6. Insert a 1/4" stainless steel bolt of the appropriate length through that hole. Install a locking nut (not Nylox) or a common nut with a lock washer and a drop of threadlocker. Tighten it with the nut on the inside. (Some customers have used sheet metal screws to hold the mufflers in place, but such screws tend to quickly vibrate loose. Please avoid this method!)
  7. When the mufflers are securely fitted to all eight pipes, the headers are ready to be installed on the engine.
Alert
Sanderson Headers does NOT provide holes for mounting or the retention fasteners for the muffler inserts due to possible liability issues. Safe installation and proper securing of the insert is the responsibility of the customer or installer.
Have questions? Please ask!