Zoomie and Chopster Replacement Baffles

Zoomie Length

Most Zoomie headers are offered in two lengths, either a standard 16″ (40.64 cm) or a longer 19″ (48.26 cm). (Big block Chevy Zoomie headers are a specific style and only one length). It is relatively easy to determine the length needed for the application. To be clear, 99% of all applications will use the standard 16″ length. The longer 19″ version requires a much higher chassis or engine location to allow necessary ground clearance.

To provide a simple example, the header should not hang down below the bottom of the wheel. However, this will vary depending on the wheel and tire profile. In the graphic below, a low-profile tire provides less ground clearance; therefore, the bottom of the header should maintain a higher value from the ground.

Many like to have that scraping-the-ground look on their street rods. However, that sort of look is best suited for trailered show vehicles and not those expected to travel city streets, including driveways, v-drains or dips, speed bumps, or other hazards that could damage the Zoomie header set.

Baffle Installation

Zoomie and Chopster Header Baffle Inserts:

Due to possible liability issues, Sanderson does NOT provide mounting holes for mounting the muffler baffle inserts. The customer or installer is responsible for the safe installation and proper securing of the insert.

Baffle Installation Procedure:

1. First, make sure the inserts are the correct size for the application. Sanderson’s 1.875″ (1-7/8″) inserts are for small block engine applications, and the 2.250″ (2-1/4″) inserts are for big block engine applications.
2. For NEW installations – Notice that one end of each Sanderson muffler insert is partly closed off with a welded washer.
3. Use a tape measure to determine the depth of the insert from the end of the tube. Use that measurement to mark the inside of the header tube. The insert depth should be held up slightly from the short-side radius at the lower bend and not bottom out (see image below). Measure the insert depth for every tube.
4. Insert the muffler into one of the header pipes with the partially closed-off end first. DO NOT FORCE. The insert should be snug but not too tight.
5. There are various methods to secure the insert. Either drill a hole slightly in front of the insert and install a stove bolt and locknut (or use red Loctite), or drill and tap directly into the baffle ring, using an appropriately sized bolt with a small amount of red Loctite on the bolt threads
   1. NOTE: Some customers have used sheet metal or self-drilling/tapping screws to hold the mufflers in place, but such screws tend to vibrate loose.
6. When the mufflers are securely fitted in all eight pipes, the headers are ready to install on the engine.