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Making Headers

Discussion in 'Builds and Fabricators Forum' started by DanStew, Jul 8, 2006.

  1. Jul 8, 2006
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
    Messages:
    4,585
    Not that i am going to do it, but i jsut want to clear up how they are made. I know how to get them to the flange to the motor and do the bends, but how do you weld them together for the collector? It seems like you could get to all the joints to weld them up and then an exhaust leak would be there. How do they do it?
     
    DanStew, Jul 8, 2006
    #1
  2. Jul 8, 2006
    $ sink

    $ sink Gazillians of posts

    Virginia Bch
    Joined:
    Nov 25, 2004
    Messages:
    1,373
    I have a book on metal fabrication (about 1980 vintage) that shows how to make a little sheet metal pyrimid shape to weld in the middle of where all of the pipes come together at the end. then with a perimiter weld all of the way around the collector, no leakage.

    never tried it but intend to some day
     
    $ sink, Jul 8, 2006
    #2
  3. Jul 8, 2006
    neptco19

    neptco19 That guy....

    Athens, GA
    Joined:
    Sep 26, 2003
    Messages:
    1,381
    Let me see if I can find some pics...

    But you can cut the pipes with a chop saw or band saw so that they all merge into one....
     
    neptco19, Jul 8, 2006
    #3
  4. Jul 8, 2006
    neptco19

    neptco19 That guy....

    Athens, GA
    Joined:
    Sep 26, 2003
    Messages:
    1,381
    Heres some I saved a while back..

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
    neptco19, Jul 8, 2006
    #4
  5. Jul 8, 2006
    Old Bill

    Old Bill Aggressively passive....

    Really Southern...
    Joined:
    Nov 12, 2004
    Messages:
    822
    Now that guy can weld! I need to practice more....
     
    Old Bill, Jul 8, 2006
    #5
  6. Jul 8, 2006
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
    Joined:
    Sep 22, 2002
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    5,349
    That was done with a TIG welder. The buddy of mine Rodney that welded my saginaw stuff to my frame welds just like that, super clean looking.
     
    Mcruff, Jul 8, 2006
    #6
  7. Jul 8, 2006
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
    Joined:
    Sep 22, 2002
    Messages:
    4,585
    i see how it is doing it there. but do all headers, have the collector made like that, then up higher on the tube, the header is welded to the collector? What i am getting at, the old headers i had, i didnt see any makrs to idicate that it was a two piece job at the bottom. Down tubes = piece 1, and the collector with tubes comeing out = piece 2. It looks to me that all jsut met at the colelctor and welded up. I am assuming now, that they would have welded them on the inside, rather than try to get a filler rod in between the tubes when the collect in the center. Very cool pics there. I know headers allow more efficient exhaust, but is there a way to bend the tubes that will make the headers perform badly?
     
    DanStew, Jul 8, 2006
    #7
  8. Jul 9, 2006
    oldjeep

    oldjeep Sisyphus at work

    Victoria, MN
    Joined:
    Sep 19, 2003
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    267
    The redneck way ;)

    [​IMG]
     
    oldjeep, Jul 9, 2006
    #8
  9. Aug 25, 2006
    ScottP66CJ

    ScottP66CJ Member

    SoCal
    Joined:
    Oct 16, 2002
    Messages:
    59
    I have a follow up to making headers. I am gathering the parts to make my own inside the frame headers for my 225. I need to get ahold of a drawing of the header flange to the head or a sample that I can use to have some flanges cut out.

    Can anyone help? I can have as many cut out as we need. If anyone is interested. I just don't have a flange to use as a sample.

    Thanks
    Scott
     
    ScottP66CJ, Aug 25, 2006
    #9
  10. Aug 25, 2006
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
    Joined:
    Mar 4, 2003
    Messages:
    5,470
    What would it cost? How thick will the flanges be? I used to make headers years ago (no TIG - Oxy setup) and have thought about making a set of block huggers as well. I only have new headers I bought from AA, but might be able to make a pattern for you.
     
    Warloch, Aug 25, 2006
    #10
  11. Aug 25, 2006
    ScottP66CJ

    ScottP66CJ Member

    SoCal
    Joined:
    Oct 16, 2002
    Messages:
    59
    The flanges will probably cost around $12 to $15 each. That is based on other items I have had cut. I want to have them cut out of no less than 3/8" plate. Maybe even 1/2".
     
    ScottP66CJ, Aug 25, 2006
    #11
  12. Aug 25, 2006
    Hansh

    Hansh Going Mobile

    SE Wisconsin
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    Dec 7, 2004
    Messages:
    425
    Why not use the manifold as your template? Trace it, cut it, flip it.
     
    Hansh, Aug 25, 2006
    #12
  13. Aug 25, 2006
    tomcam

    tomcam Member

    Savannah Tn.
    Joined:
    Jul 31, 2005
    Messages:
    89
    couldnt you just trace the flg.of a cast manifold. ive thought about making a set? actually just one for my f-head I dont know if it would help or not.
     
    tomcam, Aug 25, 2006
    #13
  14. Aug 28, 2006
    ScottP66CJ

    ScottP66CJ Member

    SoCal
    Joined:
    Oct 16, 2002
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    59
    I will probably end up using a manifold for the template.

    THanks
     
    ScottP66CJ, Aug 28, 2006
    #14
  15. Sep 10, 2006
    A Mandery

    A Mandery Member

    Indianapolis,...
    Joined:
    Dec 2, 2003
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    138
    I have doing some research on this one. I would like a custom header to ease the installation of Saginaw steering. The stock header for the 231 is in the path of the steering shaft. Fenderwell headers will not work with the turbo set up. The company in the link has a kit including flange and U bends. Quite pricey. I only need one and I have not asked if they will split the kit. Also not sure I am up to the welding. www.headersbyed.com AM
     
    A Mandery, Sep 10, 2006
    #15
  16. Sep 10, 2006
    A Mandery

    A Mandery Member

    Indianapolis,...
    Joined:
    Dec 2, 2003
    Messages:
    138
    I have doing some research on this. I need a custom header inside the frame rail to ease a saginaw conversion. The steering shaft hits the tube of the 231 factory header. The company in the address offers custom flanges in several thicknesses and mandrel bends in a kit. Much pricier than discussed above but guaranteed flat. I have not tried this as I am not sure my welding skills are up to it. www.headersbyed.com am
     
    A Mandery, Sep 10, 2006
    #16
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