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Old 02-01-2001, 07:08 AM   #1
mhj
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Question home made headers?

Anyone try to fabricate their own headers (turbo or not)? It seems pretty straight forward if you just buy some mandrel bent pipes from JC Whitney and if you know how to weld.
The flanges can be made by tracing some gaskets and using a scroll saw and drill press.

I'd try, but I don't have a welder and I no longer have a garage

I think a home made intake manifold should be just as easy.

Anyone agree? Anyone think I'm on some serious crack?

[This message has been edited by mhj (edited February 01, 2001).]
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Old 02-01-2001, 07:13 AM   #2
m750
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CRACK!
J/K not anything I'd try at home...
AO
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Old 02-01-2001, 08:17 AM   #3
Scooby2
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You couldn't buy the right shape from JC Whitney in the first place, second the flanges need to be perfect. I priced having them done from my local muffler shop and they would do it for $750.00 and no garrantee as to how they would flow. I left it to the experts on the headers and went with the Borla (and no I don't have a CE light).
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Old 02-01-2001, 09:14 AM   #4
8Complex

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You could do it. And referencing the above post, I don't think the flanges need to be perfect, but matching the flanges on the existing exhaust (rather then the gaskets) to within a good tolerance and you should be fine. The hole spacing for bolting it up, the thickness & material of the flange, and the location of the opening for the exhaust port are your real concerns.
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Old 02-01-2001, 09:53 AM   #5
mhj
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I saw a picture of a professionally made header (I think it might have been a Borla...although it did look like a turbo header) and it looked like it was made of simple 90 degree elbows, straight sections, and a couple of 180 degree pieces (to equalize the length on the passenger side). The hardest parts looked like the collectors where the welds and the pieces of metal looked pretty fancy. It's not rocket science, though.
Making the flanges should be the easiest part. It's just a lot of tracing, cutting and drilling thick steel plates.
A flexible exhaust coupling could give more slack in how precise the pipe lengths have to be.

I would try it as a winter-long project, but like I said, I don't have a welder, garage or bandsaw.

Oh well...just curious as to whether it could be done.
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Old 02-01-2001, 12:05 PM   #6
CRZ_MSL
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Yes, it CAN be done. But even if I had a welder in my garage I would still leave it to the professionals.

Consider the cost of one messed up prototype because you didn't realize that you needed to notch the mounting flanges to prevent thermal induced fracture, against the cost of paying someone who has done dozens of custom headers, and knows ahead of time what will/won't work.
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Old 02-01-2001, 12:16 PM   #7
8Complex

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Ahhhhhh, but that is the beauty of a prototype, you can hack it up and reweld stuff to it and do it right after you find out what is wrong.
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Old 02-01-2001, 12:24 PM   #8
XT6Wagon
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Yes you can, but stay away from JC whitney as thier stuff is much more expensive than you can find it elsewhere

Visit www.headersbyed.com for some thoughts and ideas

Visit www.Jegs.com for cheap Mandral bends.

Flanges are easy to make depending on how good you want them to be. Make sure you use atleast 3/8" Flatstock as thats as thin as you can reliably go.
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Old 02-01-2001, 08:32 PM   #9
Gerry
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Do yourself a favor..Unless your a welder by trade forgettabout it I bought a "kit" from headers by ed for my camaro. I mean i have done some tig and mig welding since my pops owns a structural steel shop, but I never thaught it would be so hard to weld up a set. It turned out that I trashed the kit lost $300 smackers and spent another $1,600 to have Cooks or as I say "Crooks" make me a 3" custon equal length system. But I hafta say that they are a work of art....Gerry
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Old 02-01-2001, 08:58 PM   #10
Bonzo
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Gerry makes a good point. If you are not a welder or not used to welding thin material I would leave it to someone who can. If you can weld it is like plumbing. As soon as I can live w/o my scoob this spring it will be in the air (on jacks) to make a set. I am part owner of a company that sepcializes in exhaust research, testing and mfg. I will be making the complete system utilizing our hydrofroming process to form the tubes. This is unlike anything that has been done to date. All I can say is the walls of the tube will not be paralell The intake will also be made at or near this same time. material will be .036" 304 stainless steel. Relatively thin, but thats ok, if it fails I can fix and reinforce. If it works....stay tuned
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