I have been trying to find any sort of aftermarket exhaust for my 05 jaguar s-type 4.2L v8 sport but I have not had anny luck, does anyone know where I can find headders... or do you know someone who can custom make them?

 

Well that's an old question with a long trail of answers that have changed over time.
Short answer is not anymore.

Some background which I am sure you know? The Ford Thunderbird, Lincoln LS and the Jaguar S-Type are all the same under the sheet metal.
They used somewhat different engines. The Jaguar got the larger more powerful version of the engine while the LS/T-Bird had to settle for a smaller 3.9L version.

First here are some very nice headers.




Here is a set installed on a Ford Thunderbird. Since this is the only convertible made using this platform note the large "X" brace under the car to stiffen the chassis because of no steel roof. This brace will also fit the LS and S-Type.




This was VERY big news back around 2012-2013 or so. Stainless Works made them and they are still in business today. However they no longer offer these headers.
Stainless Works

There was only one pair sold that I ever heard of and it went to an LS guy who did install them. He said "Never again!" He also ended taking them back off and tried to sell them on to someone else. At that time several guys from the S-Type forum were interested. There was one installation problem and that was the EGR hook up. The LS was a bit different from the S-Type. You can see the red arrow in the above picture. The LS EGR hooked up much lower on the exhaust header and required the additional tube shown above.

That meant they would fit the S-Type but some fabrication would be required to adapt the Jaguar EGR set-up. But nobody ended up buying them and it kind of disappeared and crashed to the ground. Same problem we always have and that's just lack of demand. Not many owners of these cars want headers and even less when the cost is factored in. Small production runs means very high prices!

You could start by contacting them but I don't know what kind of budget you have? As one off fabricated headers could easily run into the thousands of dollars but again since they did make a pair back in the day maybe they still have the drawings around to re-make a set??
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