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Chevy C5 Corvette Shorty Step Header CARB Legal #FCOR-0257


Product Details

Chevy C5 Corvette Shorty Step Header CARB Legal #FCOR-0257

Precision crafted using 100% T-304 stainless steel and mandrel bending, this exhaust system is manufactured as a direct bolt-on replacement for the factory system. By utilizing the factory mounting locations this system requires absolutely no cutting, welding, or modifications for installation. All Billy Boat Exhaust systems for the C5 come complete with mounting hardware and are a direct replacement for stock exhaust systems. Attention to detail in manufacturing means easy installation. No machining. No down time. Just a faster, better sounding, better looking and more muscular Corvette right out of the box. Guaranteed for life against corrosion, rust or burn through and two years for materials and workmanship.


Built entirely of T-304 stainless steel, Billy Boat Exhaust Shorty Headers for the C-5 Corvette are direct replacement parts for the factory equipment. Billy Boat Exhaust is the originator of the LS1 shorty header. Incorporating the correct firing order Billy Boat uses a stepped tube design with CNC mandrel bent 1.625″ to 1.750” primary tubes that are paired into a hand fabricated merge collector for optimum exhaust gas scavenging, unlike most header manufacturers who settle for an open collector. In addition to a performance increase of 15 rear wheel horsepower, Billy Boat Performance Exhaust Shorty Headers weigh 15.3 pounds…that is less than half the weight of the heavy OEM cast iron manifolds.


The Billy Boat Exhaust shorty header for the C5 Corvette was designed to blend performance and emissions. The header fits in the factory location and has been tested to meet all requirements of the California Air Resources Board (CARB).  It has been awarded EO# and is legal to install in all 50 states.


Billy Boat Exhaust has had a deep commitment to building quality products, with over 3 generation of fabrication and racing experience going into the development of every part. Billy Boat uses only the finest T304 stainless steel materials and has been a market leader for over 20 years. Billy Boat designs every system for increased performance, a distinctive tone that they have spent years perfecting, and an appearance that will set your vehicle apart.

  • Mandrel bent from the highest-grade T-304 stainless steel.
  • Designed, tested, and manufactured to the finest hand-made integrity found in any exhaust system.
  • Limited Lifetime Warranty

Lifetime Warranty

Have more questions? Contact us!

The Magnuson-Moss Warranty Act makes it illegal for companies to void your warranty or deny coverage under the warranty simply because you used an aftermarket part. READ MORE…

product image WARNING: This product in the physical form it is sold does not present a hazard. However, operations including, but not limited to welding, brazing, or thermal cutting can expose you to chemicals including Chromium, Nickel, Cobalt, Arsenic, Cadmium and Lead which are known to the State Of California to cause cancer, birth defects and other reproductive harm. For more information go to www.P65Warnings.ca.gov

How a Dyno Works

We’re going to quote DynoJet directly to explain how the machine works, since paraphrasing would only do you an injustice. “Power, in mechanical terms, is the ability to accomplish a specified amount of work in a given amount of time. By definition, one horsepower is equal to applying a 550-pound force through a distance of one foot in one second. In everyday terms, it would take one HP to raise a 550-pound weight up one foot in one second. So to measure horsepower, we need to know force (in pounds) and velocity (in feet per second). DynoJet’s inertia dynamometer measures power just in this way. The dyno calculates velocity by measuring the time it takes to rotate the heavy steel drum one turn. The dyno measures force at the surface of the drum by indirectly measuring the drum’s acceleration. Acceleration is simply the difference in velocity at the surface of the drum from one revolution to the next. The force applied to the drum is calculated from acceleration using Newton’s 2nd law, F=MA, (F)orce equals (M)ass times (A)cceleration. Power is coupled to the drum by friction developed between the driving tire of the vehicle and the knurled steel surface on the drum of the dynamometer.”

Calculating Torque

“When an object rotates around a point, the object’s speed of rotation depends on both an applied force and the moment arm. The moment arm is the distance from the point of rotation to where the force is being applied. Torque is the product of the force and the moment arm. For example, think about trying to spin a drum by wrapping a rope around the drum and then pulling on the rope. If the rope is wrapped around a drum of one-foot radius and pulled with 550 pounds of force, the resulting torque is 550 foot-pounds. The torque on the dyno’s drum can be calculated by multiplying the force applied by the drum’s radius. However, engine torque is not equal to the dyno’s drum torque because the gearing through the drivetrain changes the moment arm. The change in the moment arm is proportional to the ratio of engine speed to drum speed. Therefore, tachometer readings are necessary to calculate and display engine torque.”

  • The data below reflects a combined Mufflers and Header installation. 
RPM Stock Horsepower BBE Horsepower Gains
4200 208 223 +15
4600 225 238 +13
5000 245 255 +10
5400 248 268 +16
5800 257 275 +18
6200 249 266 +17
RPM Stock Torque BBE Torque Gains
4200 261 279 +18
4600 257 272 +15
5000 257 268 +11
5400 241 260 +19
5800 233 249 +16
6200 211 25 +15

Download PDF here… FCOR0257


Installation of Billy Boat’s Exhaust stainless steel headers for the 1997-2004 Corvette C5 is simple and straightforward. These headers do not require any cutting, welding, fabrication or other modifications to install. A professional can install the Billy Boat Exhaust headers using regular hand tools in 3-hours’ time. It is recommended a shop manual be referred to for removal and installation specifications.


Below are some tips to help you through the installation. If you require further assistance, please call our toll-free tech line at 888-228-7435.



  1. Disconnect the battery negative terminal.
  2. Remove the alternator from its support brackets.
  3. Remove the cosmetic plastic from the intake plenum and coil pack.
  4. Remove each spark plug and set aside.
  5. Unbolt and move coil packs out of the way. It is not necessary to undue the wiring harness. Do not mix the firing order of the coil packs up. Label if necessary.
  6. Loosen the primary O2 sensor from the collector of each exhaust manifold.
  7. Unbolt the air injection line from the top of each manifold.
  8. Unbolt the bottom (collector) of the exhaust manifold at the 3-bolt exhaust flange. This needs to be done from the underside of the car.
  9. Unbolt the top of the exhaust manifold from the cylinder head and carefully remove the manifold from the engine compartment.



  1. Apply anti-seize to all threaded components such as O2 sensors, spark plugs, bolts, etc.
  2. Reuse the factory exhaust port gasket or obtain a new one from your local Chevrolet dealer.
  3. Using the factory hardware, bolt the top of the header to the cylinder head to the factory recommended torque rating.  Tighten from the center of the flange, out.
  4. Reuse the factory-sealing ring at the 3-bolt flange connection (collector) and tighten using the supplied hardware. Tighten the supplied hardware to 35 ft-lbs.
  5. Install the factory O2 sensor and air injection line in the same manner and location as the original equipment. Reuse the original 2-bolt air feed gasket.
  6. Install the spark plugs to the factory specified torque rating.
  7. Fasten all coil packs and spark plug wires being sure the firing order is correct (refer to the service manual).
  8. Install the alternator per factory recommendation.
  9. Reconnect the battery.



  1. Prior to installation of the cosmetic plastic double check all of your work, making sure everything is tight and in its place.
  2. Start the engine and carefully listen for any exhaust leaks. If a leak is detected be sure the hardware is tightened evenly across the flange and that the gasket is properly seated.
  3. Drive the car spiritedly and listen for any rattles or leaks. Let it cool down and install cosmetic plastic.

After 500 miles are logged re-torque all of your work.

Billy Boat Exhaust Safety, Installation and Liability Statements

SAFETY: Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the installation.

  • Always wear safety glasses for eye protection.
  • Place the ignition switch in the OFF position.
  • Always apply the parking brake when working on the vehicle.
  • Block the front and rear tire surfaces to prevent unexpected vehicle movement.
  • Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
  • Do not smoke or use flammable items near or around the fuel system.
  • Use chemicals and cleaners only in well-ventilated areas.
  • Batteries can produce explosive hydrogen gas which can cause personal injury. Do not allow flames, sparks or flammable sources to come near the battery.
  • Keep hands and any other objects away from the radiator fan blades.
  • Keep yourself and your clothing away from moving parts when the engine is running.
  • Do not wear loose clothing or jewelry that can be caught in rotating or moving parts.

VEHICLE SUPPORT WARNING: Should the purchaser decide to install this exhaust product at home, be warned that car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

GENERAL STATEMENT OF LIABILITY: While we provide information for do-it-yourself installation of exhaust systems and related items, these operations are not without risk. Injury may occur during an installation or exhaust systems and their components may be damaged in the process. We are not responsible or liable for damages that may be sustained to persons or property during an installation. For this reason, we recommend professional installation as the best option when at all possible. While care has been taken in the preparation of the information contained in this web site, Billy Boat Exhaust and BillyBoatExhaust.com does not and cannot guarantee its accuracy. Anyone accessing this information does so at their own risk. It will be assumed that access indemnifies Billy Boat Exhaust and BillyBoatExhaust.com from any and all injury or damage arising from such use.

LOCAL LAWS & LIMITATION OF LIABILITY/DISCLAIMERS: Local Laws & Limitation of Liability/Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties. The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer. The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer. In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

If you have any questions please feel free to give us a call. Our direct line to the sales departments is 1-888-228-7435, ext 18. We are in Phoenix, AZ and can be reached 8am-5pm. Should you have questions that images would help explain, please email Mike at mike@bbexhaust.com.

*Please note, we do not follow daylight savings time if you are contacting us outside of Arizona.

We try to put as much information as possible within our product pages to help with application choice and the installation process. The business you purchased our product from can be a wealth of information, but should you need additional help and information, please feel free to call or our sales department.

Monday-Friday 8:30am-5:00pm Arizona time.
888-228-7435 x18 or 623-581-7600 x18

*Note that Arizona does not follow Daylight Savings Time.

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