Headers!
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Thread: Headers!

  1. #1
    Join Date
    Feb 2005
    Location
    Flowery Branch, GA
    Posts
    469

    Headers!

    I recently got a PO to build some headers for a local race car manufacturer that builds several different spec racers. I was given a rough prototype set and some jigs along with all the mandrel bends and required materials. The collectors are premade by Hedman - and fairly rough with big mig welds and gaps in the stops and starts. I don't have dies for my bender in 1.875 OD, so using U bends was the way to go.

    Fitting the tube pieces up in the jig:


    Due to obstructions in the car the headers are installed as 2 halves as you can see by that last pic.

    Welding up the primary tubes:


    Welding the primaries into the flange:


    I found the tubes flopping around on the welding table a royal pain to position, so I used a base from one of my homemade material stands to make a tube holder. It adjusts up and down, has about 180 degrees of angle sweep, and you can rotate the tubes in the v-clamp as well. This made welding everything up MUCH easier!





    And here are some pics of the complete header assembly:






    One done - 9 more to go! And, there might be 10 more following this first batch of 10!

  2. #2
    Join Date
    Dec 2007
    Location
    AZ.
    Posts
    131

    Re: Headers!

    nice work.

    JImmy

  3. #3
    Join Date
    Apr 2007
    Location
    British Columbia, Canada
    Posts
    68

    Re: Headers!

    Awesome. I love headers. Squeezing quality exhaust work into tight spots is one of those jobs that really gives a feeling of satisfaction when you are finished

    -Ryan

  4. #4
    Join Date
    Dec 2007
    Location
    forest lake minnesota
    Posts
    690

    Re: Headers!

    thanks, for the post!!! nice work. It looks like 10 headers may take a few minutes to weld. lol Daye

  5. #5
    Join Date
    Feb 2007
    Location
    jersey
    Posts
    282

    Re: Headers!

    Looking really good...very nice project
    -Graham-
    Mechanical Engineer
    Autosport Mechanic/Fabricator

  6. #6
    Join Date
    May 2006
    Posts
    4,157

    Re: Headers!

    Looks good. The HAZ is a little wide for my liking. What size Tungsten?

    This looks like it's for a import car?
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  7. #7
    Join Date
    Feb 2005
    Location
    Flowery Branch, GA
    Posts
    469

    Re: Headers!

    I guess I should have mentioned - these are all mild steel - a combination of .049 and .065 wall tubing. 1/16" tungsten, .030 mild steel filler rod. I don't know the amps; not much. The thin mild steel changes color really fast - but I wouldn't call the color change area an actual heat affected zone.

  8. #8
    Join Date
    Feb 2005
    Location
    Flowery Branch, GA
    Posts
    469

    Re: Headers!

    Oh, and it's a header for the "DP02" found here: http://www.elanmotorsports.com/?action=page.products

  9. #9
    Join Date
    May 2006
    Posts
    4,157

    Re: Headers!

    Nice stuff, I agree with the thin wall, it's a tough customer.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  10. #10
    Join Date
    Aug 2007
    Posts
    1,765

    Re: Headers!

    ive got a variety of aluminum blocks that make welding odd shaped tubes so much easier, just block it where you need it and go to town.

    (no, our bender still isnt running)
    Have we all gone mad?

  11. #11
    Join Date
    Mar 2008
    Location
    Coquitlam, BC, Canada
    Posts
    4

    Re: Headers!

    [QUOTE=TubularFab;179282]

    Due to obstructions in the car the headers are installed as 2 halves as you can see by that last pic.


    And here are some pics of the complete header assembly:




    Great job, looks good to me. I am not a certified welder like most of you guys, just a auto body man. How are the 2 header half's been held in the collector, are there small brackets and springs keeping them together?

    Martin
    I can't cut corners, must be the German in me!!!

  12. #12
    Join Date
    Mar 2006
    Location
    Yuma, Arizona
    Posts
    2,607

    Re: Headers!

    more to do? Wow, that looks exhausting!

    heheheh
    Lincoln Power Mig 350MP Ready Pak
    Lincoln Precision TIG 275 Ready Pak
    Lincoln WeldPak 100
    CK TIG TORCH gas diffuser and pyrex cup
    Thermal Dynamics Cutmaster 101
    A stout 15 yr old son to help!!

  13. #13
    Join Date
    Mar 2008
    Posts
    34

    Re: Headers!

    coooolll........... wish i could do that!

  14. #14
    Join Date
    Nov 2005
    Location
    utcia michigan
    Posts
    1,278

    Re: Headers!

    looks good to me,nice job

    Chuck
    ASME Pressure Vessel welder

  15. #15
    Join Date
    Feb 2007
    Location
    West By Golly Shelby NY
    Posts
    7,265

    Re: Headers!

    Freekin awesome. You don't need a positioner, you just built one.

    David
    Real world weldin.

    When I grow up I want to be a tig weldor.

  16. #16
    Join Date
    Oct 2006
    Location
    Ca, USA
    Posts
    5,241

    Re: Headers!

    Super job!
    MM350P/Python/Q300
    MM175/Q300
    DialarcHF

    HTP MIG200
    PowCon300SM

    Hypertherm380
    ThermalArc185
    Purox oa
    F350CrewCab4x4
    LoadNGo utilitybed
    Bobcat250
    XMT304/Optima/Spoolmatic
    Suitcase12RC/Q300
    Suitcase8RC/Q400
    Passport/Q300

    Smith op

  17. #17
    Join Date
    Nov 2007
    Location
    everywhere
    Posts
    30

    Re: Headers!

    great job..this is this kind of stuff i plan to be doing after i finish my welding course

  18. #18

    Re: Headers!

    Damn, that is nice! I just learned how to Tig weld to do something like this. I just need to find a project to attempt it. It looks fairly straight forward, but I am sure it looks a lot harder than it seems. Is there any type of calculations in making the header? I know it is equal length, but was there any rule of thumb to try and squeeze out horsepower / torque from specific length or size tubing?
    Wish I can do that.

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