How To Install Our Latest Kool Wrap Exhaust Wrap Insulation

Installing exhaust wrap correctly helps protect nearby components from radiant heat and keeps the wrap secure on the pipe. The process is straightforward, but the details matter: preparation, tension, overlap and tie placement all affect the finished result.

This guide explains how to install exhaust wrap step by step, including how much wrap you need, how to prepare the pipe, whether you need to soak the wrap, how much overlap to use and what to expect when you start the engine.

For available materials, sizes and ratings, see the Kool Wrap exhaust heat wrap range.

What you need to install exhaust wrap

Before starting, gather everything you need so you can complete the job without stopping halfway through.

You will need:

• Exhaust wrap
• Stainless steel ties
• Scissors or a sharp cutting tool
• Gloves
• High-temperature exhaust paint, if you plan to seal the finished wrap
• Jack stands, ramps or a hoist if required
• Basic tools for removing the exhaust, if you choose to take it off the vehicle

Work on a completely cool exhaust system. Exhaust components can remain extremely hot long after the engine has been switched off.

If you are removing the exhaust, label or photograph the connections before disassembly so everything can be returned to its original position.

How much exhaust wrap do I need?

The amount of wrap required depends on pipe diameter, pipe length, the number of bends and the amount of overlap.

A useful starting point is to calculate the circumference of the pipe, then allow for the additional length created by wrapping each turn with overlap.

For a straight section:

Wrap length ≈ pipe circumference × number of turns

The number of turns depends on the length of the pipe and the width of the wrap.

As a practical example, one metre of 50mm pipe wrapped with 50mm wrap at approximately 6mm overlap per turn needs about 3.7m of wrap. Add around 10% for bends and tie-offs.

For a four-cylinder set with 38mm primaries approximately 0.8m long, the calculation comes out near 10.2m, so a 15m roll gives you a safer margin.

If you are unsure, measure each pipe section and allow extra material for bends and finishing the ends.

How to install exhaust wrap

1. Remove and clean the exhaust

Remove the headers or exhaust sections if the job allows it. Working on the bench makes it easier to maintain even tension and inspect the entire pipe.

Clean the pipe thoroughly before wrapping. Remove oil, grease, dirt, loose rust and other contamination.

If you are wrapping mild steel, deal with surface corrosion before installing the wrap. Apply high-temperature exhaust paint where appropriate and allow it to cure according to the paint manufacturer’s instructions.

Stainless steel should be clean and free from oil and dirt before wrapping.

2. Measure and plan the wrap

Measure the pipe sections before cutting the wrap.

Start at the narrowest end of the pipe. On a header, this is usually the head end. On a straight exhaust section, it is normally the front.

Plan where your joins, bends and finishing points will be. Avoid placing unnecessary joins in awkward locations.

3. Start the first turn

Fold the first few centimetres of wrap back on itself.

Position the folded end at the starting point and lock the fold underneath the first turn. This helps prevent the cut edge from fraying as you work.

Keep the wrap straight and apply consistent tension as you move along the pipe.

4. Wrap with consistent tension

Work around the pipe one turn at a time.

Pull the wrap firmly enough to keep it secure, but do not stretch it excessively. The goal is an even, consistent fit without loose sections or bunching.

Follow the shape of the pipe through bends rather than forcing the wrap to sit flat where the pipe changes direction.

For complex headers, take your time around the collector and tighter bends. Uneven tension in these areas can create gaps or excessive overlap.

5. Keep the overlap at about 6mm

Overlap each turn by approximately 6mm.

Kool Wrap’s installation guidance allows around 5 to 8mm of overlap. Keeping the overlap consistent gives the finished wrap an even appearance and avoids unnecessarily building up thickness.

Too much overlap adds thickness and can hold more heat and water against the pipe.

6. Use one layer

One layer is the standard fit in the Kool Wrap installation guide.

Adding extra layers increases the thickness around the pipe. It can also hold more heat against the pipe wall and take longer to dry if the wrap becomes wet.

Unless your application specifically requires otherwise, install one even layer.

7. Secure the wrap with stainless steel ties

Secure the wrap at the starting point, along the pipe and at the finishing point using stainless steel ties.

Place the ties where they hold the wrap firmly without cutting into the material.

Tighten each tie securely, then turn or position the lock away from areas where it could contact wiring, boots, hoses or other components.

Check the finished wrap for loose edges or sections before reinstalling the exhaust.

8. Finish the ends carefully

At the end of the pipe, fold the wrap neatly and secure it with a stainless steel tie.

Avoid leaving loose material hanging from the end of the wrap.

Check around flanges, welds and other areas where the wrap may need to be trimmed for a clean fit.

9. Keep sensitive components bare

Do not wrap components that should remain exposed.

Leave O2 sensors and flex joints bare. Leave catalytic converters bare unless the vehicle manufacturer specifically allows them to be wrapped.

The wrap should remain on the appropriate exhaust pipe sections rather than being extended over components that require their own operating or cooling conditions.

10. Consider sealing the finished wrap

You can optionally seal the completed wrap with high-temperature exhaust paint.

This can help lock down loose fibres and protect the finished surface.

Follow the paint manufacturer’s application and curing instructions.

How to heat cycle new exhaust wrap

After installation, reinstall the exhaust and check that the wrap is clear of wiring, hoses, brackets, bodywork and other components.

Start the engine and allow the exhaust to heat gradually.

New exhaust wrap can produce light smoke and an odour during the first heat cycles. This is caused by binders in the material burning off and is generally normal.

The smoke should reduce and clear after the first few runs.

If smoke continues heavily, or you notice an oil or fuel smell, switch the engine off and investigate. Contamination on the wrap or an exhaust leak can produce different symptoms.

If you use a turbocharged vehicle, make sure surrounding components have sufficient clearance. If you also use a turbo blanket, check the manufacturer’s fitting instructions for the complete setup.

How long should you soak exhaust wrap?

You do not have to soak it at all.

Kool Wrap exhaust wrap does not need wetting before installation. Some installers lightly spray wrap because damp material can pull tighter and shed fewer fibres during installation.

If you dampen the wrap, run the engine soon after installation so the heat can dry it out.

Do not leave damp wrap sitting on the exhaust pipe.

How much overlap should exhaust wrap have?

About 6mm per turn is a good target.

Kool Wrap’s installation guide allows approximately 5 to 8mm of overlap.

More overlap than necessary builds additional thickness around the pipe. It can also hold more heat and water against the exhaust.

Aim for a consistent overlap from one end of the pipe to the other.

Do you wrap from the top or the bottom of the pipe?

Start at the narrowest end.

On a header, this is usually the head end. On a straight exhaust section, it is generally the front.

Fold the first few centimetres back on themselves and lock the fold underneath the first turn. This prevents the cut end from fraying as you continue wrapping.

Work towards the wider section while maintaining consistent tension and overlap.

Can you install exhaust wrap without removing the exhaust?

Yes.

Exhaust wrap can be installed while the exhaust remains on the vehicle, particularly when access is good and the vehicle is safely supported.

However, working with the exhaust removed generally makes the job easier. It takes longer to maintain even tension when working underneath a vehicle, and you cannot inspect the far side of the pipe as easily.

If the job allows it, remove the pipes and wrap them on the bench.

Why does new exhaust wrap smoke?

Light smoke during the first heat cycles is normal.

Binders in the wrap burn off as the material reaches operating temperature. You may also notice an odour during the first few runs.

The smoke should reduce and clear after the first few heat cycles.

Smoke that continues, becomes excessive or smells of oil or fuel should be investigated. It may indicate contamination on the wrap or an exhaust leak.

Final checks after installation

Before considering the job finished, check the entire exhaust system.

Look for:

• Loose or missing stainless steel ties
• Uneven or excessive overlap
• Frayed edges
• Gaps in the wrap
• Wrap touching wiring, hoses or other components
• Wrap rubbing against the chassis or engine mounts
• O2 sensors or flex joints accidentally covered
• Signs of oil or fuel contamination
• Exhaust leaks around joints and flanges

Once the system has completed its first few heat cycles, allow it to cool completely and inspect the wrap again.

For information on what to look for as the material ages, read how long exhaust wrap lasts.

If you are also concerned about the condition of the exhaust underneath the wrap, see whether exhaust wrap can damage extractors.

Need help choosing?

Not sure how much wrap your exhaust system needs? Send Kool Wrap your pipe sizes and lengths, or call 1300 44 33 34.

You can compare available wraps, ties and related products in the exhaust heat wrap range.