DC Sports started as a header design outfit contrived by twin brothers and fabricators Darrell and Darrick Contreras. In 1987, American Honda approached the two to build a header for an '88 CRX race car. The design was impeccable, and Honda loved the header so much that they had the Contreras brothers develop products for their other cars, thus leading to the birth of the DC Sports as a manufacturer.
Over time, the sport-tuning crowd caught on to the precision and attention to detail that DC Sports put into their products and made the company a household name among average consumers and aftermarket companies alike. DC Sports eventually expanded their product line up with a wide range of components including exhausts, chassis stabilizing equipment, and other accessories. In 2004, AEM acquired DC Sports to combine the leading exhaust manufacturer with the leading air filter manufacturer to offer the tuning market top-quality engine breathing products.
We trekked out to its Corona, Calif., location to follow along as Mitch Terry, a research and development team member for DC Sports, gave us a tour on how their headers are made.