All Exhaust Systems by Engine Model - Big Block Chevy 454 / 502, 7.4L / 8.2L Exhaust Systems

Stock Mercury Replacement BBC 454/7.4L and 502/8.1L Cast Iron Exhaust Kit w/ 6” Spacer
Mercury Big Block Chevy Exhaust Kit with 6 Inch Spacer. This kit has 3 Inch Elbow Kit used with 4" exhaust hose. For 1981 & Up.

Qty	Description	OEM #
2	Exhaust Elbow	807988A2
2	Exhaust Manifold Assy.	807078A6
2	Spacer 6"	807477A2
2	Gasket-Fresh Water	27-860231
2	Gasket-Raw Water	27-863724
2	Gasket	27-863726
2	Gasket	27-46820
8	Screw	10-12244
8	Screw	10-43749
2	Hose Fitting w/ Drain Plug Kit	22-806926A1

Stock Mercury Replacement BBC 454/7.4L and 502/8.1L Cast Iron Exhaust Kit w/ 3” Spacer
Mercury Big Block Chevy Exhaust Kit with 3 Inch Spacer. This kit has 3 Inch Elbow Kit used with 3" exhaust hose. For 1981 & Up.

Qty	Description	OEM #
2	Exhaust Elbow	98504A3
2	Exhaust Manifold Assy.	807078A6
2	Spacer 3"	807476A3
2	Gasket-Elbow	27-863724
2	Gasket-Elbow	27-863726
2	Gasket-Manifold	27-46820
8	Flange Serrated Nut	11-49838
8	Stud	16-97520
2	Hose Fitting w/ Drain Plug Kit	22-806926A1

Stock Mercury Replacement BBC 454/7.4L and 502/8.1L Cast Iron Exhaust Kit w/ 6” Spacer
Mercury Big Block Chevy Exhaust Kit with 6 Inch Spacer. This kit has 3 Inch Elbow Kit used with 3" exhaust hose. For 1981 & Up.

Qty	Description	OEM #
2	Exhaust Elbow	98504A3
2	Exhaust Manifold Assy.	807078A6
2	Spacer 6"	807477A2
2	Gasket-Elbow	27-863724
2	Gasket-Elbow	27-863726
2	Gasket-Manifold	27-46820
16	Screw	10-12244
2	Hose Fitting w/ Drain Plug Kit	22-806926A1

OMC / Volvo Complete Exhaust Kit- BBC V8 454/502 CID (7.4/8.2L)

For 1991 & up applications.
Standard height 4" Hose OMC/Volvo risers 7-3/4" Tall. Used on OMC 89-98 and Volvo 94 and Up

OMC / Volvo Exhaust Kit w/ Hi-Rise Single-Piece Elbow - BBC V8 454/502 CID (1991 & Up)

Tall height, 4" Hose OMC/Volvo risers, 11" Tall. 

Mercruiser Big Block Chevy Exhaust Manifold Kit 454/502 89011A8 / 807078T08

Qty	Description	OEM #
1	Exhaust Manifold	807078T08
1	Hose Fitting w/ Drain Plug	22-806926A1
1	Gasket-Elbow	27-863724
1	Gasket-Manifold	27-46820

• Direct Replacement for Mercruiser Big Block Chevy 454/502 Manifold
• Manifold Constructed from Cast Iron and painted with black corrosion resistant paint.
• Individual Runners for Improved Performance over Stock Manifold
• Replaces Mercruiser #807078T10, 80707T08 and 89011A8, 807078A6 Manifolds.
• Can use with 4" or 3" Riser
• Includes Gaskets
• 3-Year Warranty
• Sold Each.

Exhaust Manifold

For OMC: MODEL 7.4/8.2L - V8 B.B., GM 454/502 CID (1991 & UP)
For Volvo: MODEL 7.4/8.2L - GM 454/502 CID V8 (1992 & UP) #3861459

Standard Big Block Chevy Freshwater Merc Kit 36" Wide - STOCK Measurements

THE ULTIMATE "FRESH WATER" EXHAUST SYSTEM

Finally an affordable alternative to all stainless steel water jacketed headers. For the thousands of pleasure boaters "NOT" affected by the corrosion problems associated with Salt Water there is at last the availability of a true tubular header system for the Fresh Water boater. These headers are designed to be a replacement for Mercury manifolds. However, they terminate approximately 8" aft of stock manifolds and are projected to meet the exhaust tips providing they are in the stock location. Low Port Headers are also available for under the swim step applications. Standard width headers will have about 1/2" clearance between header and tall style Moroso valve cover. Headers come complete with bolts, gaskets, water fittings, pet cocks, etc. (less 4" hose and 4" hose clamps). Factory oil filter requires relocation.

THE LIGHTNING CONSTRUCTION DIFFERENCE IS WHAT COUNTS !
Our Magnum header starts with Mandrel bent 316L stainless steel interior tubes. The exterior tubes are Mandrel bent heavy wall steel tube (.074). The tubes are then mechanically etched by sand blasting and then assembled. Finally,a corrosion resistant silicone ceramic coating is applied to the interior of the header while the exterior receives a powder coat finish.

ALL THIS PLUS THE BEST 2-YEAR WARRANTY IN THE INDUSTRY

Through continuing research Lightning Mfg. has developed a Dual Porcelain Coating that resists corrosive water environments. Now able to apply the same high tech coating to the fresh water series of steel outer lined thus aiding in the prevention cracking and deterioration.

NOTE: LIGHTNING HEADERS HAVE A 4-6 WEEKS BUILD TIME.

Standard Jacketed Header - Big Block Chevy Jet Drive 36" Wide

These headers are designed to be a replacement for Jet manifolds. However, they terminate approximately 8" aft of stock manifolds and are projected to meet the exhaust tips providing they are in the stock location. Headers will have about 1/2" clearance between header and tall Moroso valve covers. Headers come complete with bolts, gaskets, water fittings, pet cocks, etc. (less 4" hose and 4" hose clamps). Factory oil filter requires relocation.

LIGHTNING PERFORMANCE
When comparing performance exhaust systems it's good to understand the different systems on the market today and the performance demands of your engine. Understanding how a header works will help you decide on which exhaust system is best suited for your application.

Headers have two basic functions. First is to simply relieve back pressure. For example, when looking at a manifold you see a 4" diameter exhaust hose, but the actual exhaust gas opening is about 2-1/2" diameter. Most performance manifolds and some header manufacturers use a 4" exhaust hose and 3" or 3-1/2" OD exhaust gas tube. All of these headers use a 4" OD exhaust gas tube and a 5" water jacket tube until the water gets introduced into the exhaust gas stream, then it gets reduced from 5" to its 4" exhaust hose diameter. At no time does the exhaust gases see a diameter smaller than 4" OD. When looking at these exhaust gas openings consider their area not their diameter. For example, a 4" OD opening has an area of approximately 12.56 sq. in. A 3-1/2" opening has an area of approximately 9.62 sq. in.That is 25% smaller! A 3" opening is approximately 7.06 sq. in. and a 2-1/2" opening is approximately 4.90 sq. in. which is 60% smaller.

LIGHTNING HORSE POWER COMPARISON
Performance figures on headers vary considerably. As a rule, the higher horsepower engines benefit more than the lower horsepower engines. For example, the 330 hp Mercury engine will gain approximately 50 to 75 rpm, where as the 365 hp Mercury engine will gain approximately 300 to 400 rpm (45 hp). Blown engines gain up to 800 rpm (80 hp). Of course this is comparing these headers against stock Mercury center rise manifolds.

LIGHTNING CONSTRUCTION
Our Magnum header starts with Mandrel bent 316L stainless steel interior tubes. The exterior tubes are Mandrel bent heavy wall steel tube (.074). The tubes are then mechanically etched by sand blasting and then assembled. Finally, a corrosion resistant silicone ceramic coating is applied to the interior of the header while the exterior receives a powder coat finish.

ALL THIS PLUS THE BEST 2-YEAR WARRANTY IN THE INDUSTRY

Through continuing research Lightning Mfg. has developed a Dual Porcelain Coating that resists the harshest of salt water environments. Now as an option they are able to apply the same high tech coating to a 316L stainless steel lined header once thought to be the cracking alloy and render it crack resistant.

NOTE: LIGHTNING HEADERS HAVE A 4-6 WEEKS BUILD TIME.

NOTE: All Lightning Headers are now built to order by quote only. Please select your options below and we will have a price and turn around time quoted to you as soon possible. Please make sure your contact information (e-mail address and phone number) are correct when placing an order for a quote. 

All orders of Lightning Headers will require you to provide measurements, see these diagrams:

Lightning Jet Headers
Lightning Mercury Headers
Lightning Generic Headers

Please select all the options below you wish to have on your headers. By ordering this item you are asking for a quote only. 

NOTE: LIGHTNING HEADERS HAVE A 4-6 WEEKS BUILD TIME.

Hi-Torque Replacement Big Block Manifolds Only (pair)

Set of replacement manifolds only. No pipes. If you find yourself in need of maintenance accessories - we've got them!Gaskets, Clamps, Manifolds, Sealers.  We've got it all!

Big Block GM Hi-Torque Standard Kit

The Hi-Torque manifolds feature state of the art design with a single wall internal casting that is enclosed in a press formed aluminum jacket creating a fully water cooled manifold. A highly polished stainless steel riser comes standard as well as bolts, gaskets and fittings. This system is also covered with an exclusive 5 year warranty. These systems are compatible with silent choice and similar type exhaust diverter systems

Industry wide, Stainless Marine exhaust systems are recognized for increased horsepower, remarkable weight savings, an exclusive five-year warranty and an incredible value.

Tests by both Hot Boat and Trailer Boat Magazines revealed increases of 3.2 to 6.5 MPH on MerCruiser Big Block powered 22'-24' boats.

The unique construction results in the heaviest manifold weighing only 23 pounds A huge savings compared to cast iron Stainless Marine is one of the top quality and least expensive systems available today. Note: All systems based on Bravo applications.

All kits include: Shift, Module, and an Oil Filter Bracket

Big Block GM H/P Long Riser Kit

This system was designed for mildly modified factory engine packages. It shares the same features as the systems listed above, except its long tailpipe discharges water later in the exhaust stream. This provides some flexibility for mild cam shaft changes. Please consult us for cam shaft compatibility. A measurement sheet must be filled out when purchasing.

Big Block GM Hi-Torque Dry System

This system is designed for heavilymodified engines with large cam shafts and/or high compression It will deliver maximumhorsepower and reliability on naturally aspiratedengines Keep in mind, all dry systems are very loud

Stainless Marine Hi-Torque Gen III - Big Block GM, 4-1/2" Tailpipe, Up To 540 Cubic Inches And Over

These systems are incredible performers They holdboth APBA catamaran and V-bottom records This systemhas recorded speeds in excess of 160 MPH and isdesigned for the person looking for true header performancewith reliability of a manifold system This system isdesigned for large cubic inch and supercharged motors.

Industry wide, Stainless Marine exhaust systems are recognized for increased horsepower,remarkable weight savings, an exclusive five-year warranty and an incredible value.

Tests by both HotBoat and Trailer Boat Magazines revealed increases of 3.2 to 6.5 MPH on MerCruiserBig Blockpowered 22'-24' boats.

The unique construction results in the heaviest manifold weighing only 23 pounds.A huge savings compared to cast iron. Stainless Marine is one of the top quality and leastexpensive systems available today. Note: All systems based on Bravo applications.

Stainless Tail Pipe, Large Collector, V-Band Clamps(No Bolts), 15" Long Runners. Press Formed Water Jacket for Better Cooling. Thick SingleWall Casting. Better Flow Capacity (Larger than Big Tube Headers)

Stainless Marine Hi-Torque Gen III - Big Block GM, 5" Tailpipe, Up To 600 Cubic Inches And Over

These systems are incredible performers They holdboth APBA catamaran and V-bottom records This systemhas recorded speeds in excess of 160 MPH and isdesigned for the person looking for true header performancewith reliability of a manifold system This system isdesigned for large cubic inch and supercharged motors.

Industry wide, Stainless Marine exhaust systems are recognized for increased horsepower,remarkable weight savings, an exclusive five-year warranty and an incredible value.

Tests by both HotBoat and Trailer Boat Magazines revealed increases of 3.2 to 6.5 MPH on MerCruiserBig Blockpowered 22'-24' boats.

 The unique construction results in the heaviest manifold weighing only 23 pounds.A huge savings compared to cast iron. Stainless Marine is one of the top quality and leastexpensive systems available today. Note: All systems based on Bravo applications.

Stainless Tail Pipe, Large Collector, V-Band Clamps(No Bolts), 15" Long Runners. Press Formed Water Jacket for Better Cooling. Thick SingleWall Casting. Better Flow Capacity (Larger than Big Tube Headers)

Thumper Power - Black Big Block Exhaust System w/Shift Bracket

Are your cast iron manifolds failing? This could be the answer. A cost effective lightweight entry level performance system. This system was designed for efficiency and reliability on stock originally equipped engines. Not silent choice compatible.

Thumper Power - Polished Big Block Exhaust System w/Shift Bracket

Are your cast iron manifolds failing? This could be the answer. A cost effective lightweight entry level performance system. This system was designed for efficiency and reliability on stock originally equipped engines. Not silent choice compatible.

Tornado Big Tube Vertical Rise Center Exit Exhaust Headers (Tailpipes NOT Included)

The "NEW" Tornado series Hardin Marine Headers were designed and breed from Hardin Marines racing heritage and achievements.  The unique center exit style of header incorporates all of the famous exclusive features that Hardin marine headers are known for like large 2-1/4" big tube primaries a must in performance style race header.  These headers will accommodate nearly any engine configuration and exit style from top hatch race exit systems to dual and triple engine tail pipe configuration’s with the greatest of ease.  Big Tube headers are designed for high horsepower applications and deliver horsepower returns that are simply unmatched.  If your in the market for big tube power supply and or need unique fit, then look no further than these Tornado Big Tube Headers.

Tailpipes are available in 4 inch and 4-1/2 inch wet or dry style.  All tailpipes are built custom to order.  Please call for details.

Custom Tailpipe Installation Example

Big Tube 2-1/4" Big Block Chevy Freshwater Merc Kit 36" Wide - STOCK Measurements

THE ULTIMATE "FRESH WATER" EXHAUST SYSTEM

Finally an affordable alternative to all stainless steel water jacketed headers. For the thousands of pleasure boaters "NOT" affected by the corrosion problems associated with Salt Water there is at last the availability of a true tubular header system for the Fresh Water boater. These headers are designed to be a replacement for Mercury manifolds. However, they terminate approximately 8" aft of stock manifolds and are projected to meet the exhaust tips providing they are in the stock location. Low Port Headers are also available for under the swim step applications. Standard width headers will have about 1/2" clearance between header and tall style Moroso valve cover. Headers come complete with bolts, gaskets, water fittings, pet cocks, etc. (less 4" hose and 4" hose clamps). Factory oil filter requires relocation.

THE LIGHTNING CONSTRUCTION DIFFERENCE IS WHAT COUNTS !
Our Magnum header starts with Mandrel bent 316L stainless steel interior tubes. The exterior tubes are Mandrel bent heavy wall steel tube (.074). The tubes are then mechanically etched by sand blasting and then assembled. Finally,a corrosion resistant silicone ceramic coating is applied to the interior of the header while the exterior receives a powder coat finish.

ALL THIS PLUS THE BEST 2-YEAR WARRANTY IN THE INDUSTRY

Through continuing research Lightning Mfg. has developed a Dual Porcelain Coating that resists corrosive water environments. Now able to apply the same high tech coating to the fresh water series of steel outer lined thus aiding in the prevention cracking and deterioration.

NOTE: LIGHTNING HEADERS HAVE A 4-6 WEEKS BUILD TIME.