Hi Gavin.

Welcome fellow Henley owner!

I have a Sierra-based Henley which also requires a fair bit of work. It, however, fortunately came with a full Stainless Steel system which was supplied by Pastiche cars. It has two boxes - a small round central box, and a larger oval unit towards the back. It was clearly made up for the Henley, but is probably very close to the original Sierra system - it may have been simply tweaked to suit, or could be completely bespoke, I don't know.

Since the Henley is no longer in production, I guess you'll have to rely on a bespoke service to have one made up. Are you into doing this yourself?! There are a number of companies who'll supply any shape of part you could need, and they'll simply require welding - or even clamping - together. Clearly, it would be worth making this up in stainless steel, so you'd only need to do it once!

There are, of course, plenty of companies that'll make up the complete system for you, but you will probably be talking of £300-400 upwards for this, possibly lots more...

Check out: Jetex to start with. I'll try and get some more names for you.

Thanks for that Donnie, I would be very surprised if I couldnt get one made up from standard bits with a tweek here and there, I've not really looked into it yet. As the car is completely stipped down with all the body panels off and interior out I cant yet drive it to an exhaust place to see what they could supply.
The exhaust is possibly one of the last jobs that I will tackle. The only down side to the exhaust that I have on just now is the noise when I start it up in the garage (more suited to a race track) not to mention as it is a side exit exhaust It nearly knocks me off my feet when I walk past it. Anyway good luck with yours, you will probably hear from me again as Im a bit of a beginer at this, but I do enjoy a challenge. Gavin

Hi Gavin.

Blimey, that's cheap!:

http://www.onlineautomotive.co.uk/search_results.php?

Mind you, it'll be mild steel, not stainless. Should give you an idea of what's required.

The Jetex website lists all the bends, straights, over-axles, etc bits you can get should you want to make one up yourself, and then it's a case of joining them up!

It's worth keeping a constant cyber-eye out for companies who make up systems to order; by the time you get to that stage, you should be pretty clued-up. They CAN vary hugely in cost.

One major advantage with a side-exit system is the increased ground clearance it offers. In fact, my Marlin will soon gain a side-exit system for just this reason. The current exhaust was hardly in brilliant condition, but a couple of sleeping policemen have made sure it won't see the upcoming MOT test!

Your 3" system sounds (oops) a bit loud, tho'.

I'm going to experiment with a 'Polyzaust' (I don't think that's spelt correctly) I bought of Ebay. Have you heard of them? It's South African, mainly Stainless Steel, but with a polycarbonate outer case - yep, it's made from plastic! Meant to have very good sound insulating properties, and is smaller and lighter than equivalent metal boxes.

We'll see!

Oops, that link doesn't take you directly to the Cortina systems. However, the 'search' facility on the left of the page will get you there!