Your "too small" dyno exhaust is a perfect example of why dyno numbers can vary from dyno to dyno. And it has nothing to do with dishonesty, fudging numbers, Incorrect weather correction or incorrect dyno calibration. Just a case of operator error (we all error sometimes) by using the wrong diameter (too small) dyno exhaust for the horsepower output of the engine. You should be able to pull the engine with the dyno exhaust on or off and it should repeat the number both ways. If you're doing header testing it's not a bad idea to make sure you test your dyno exhaust first. Otherwise your just testing for which header is best with your dyno exhaust system. Also when testing without dyno exhaust you have to make sure you have adequate airflow to keep your dyno room swept out of exhaust gasses so you don't gas out yourself or have the engine sucking the gasses in. It's best to use a pusher fan and a puller fan at each end of the room so you can move the needed amount of air through the room and be able to adjust the fanspeeds to keep the room at zero static pressure. The engine should also supplied with its own clean air that is the appropriate temperature and humidity for the conditions the engine will be used at. Like a 2.5' tube not a 8" tube. The air temp , humidity and air pressure probes should be in this tube as close to the carb as possible. That air should be supplied at high volume and low velocity and not sealed to the carburetor. Also when tuning make sure you use the air cleaner set up that will be on the engine. Sometimes budget , time or other obstacles will keep you from testing the way you should or want to. Be aware that how you test might affect your results and then do the best you can.That's funny because when I dyno'd my engine I gained 26 hp from a header swap, 2 inch to 2 inch / 2-1/8 step headers ....then I wanted to run the exhaust as it would be in the car, so we removed the dyno exhaust....it picked up another 25 hp.... So, that's a 51 HP pick up total.
There was no messing with anything except for removing a restriction.
I'll be putting this engine back on the Dyno soon if you need proof.
Crap, too long.















