First time header build

77cruiser · Post by **77cruiser** » Fri Nov 28, 2014 9:03 am

I'm going give it a shot. How many hours can be expected for a first timer?
I'm thinking at minimum 100 hrs.

900HP · Post by **900HP** » Fri Nov 28, 2014 9:12 am

You can definitely spend that much time on them.

There is a lot of good information on header construction and welding to be found on Burn's Stainless website as well as Header's by Ed.

Use the biggest radius bends that you can physically fit
an inch or two short or long from target isn't as important as having a gentle swooping tube
don't start out with a tube that has any larger area than the exhaust port you are attaching to
absolutely do not use a collector any larger in diameter than absolutely necessary

most importantly: do a search on everything ever posted by Calvin Elston (exhausted), so much to learn there.

77cruiser · Post by **77cruiser** » Fri Nov 28, 2014 9:21 am

I've read a lot of Calvin's posts just trying to learn it is a challenge, maybe I'm getting too old for this stuff.

I'm using Pipemax for the dimensions. The collector diam. from P/M wants 3.17, so going to 3 in. won't be a problem.

900HP · Post by **900HP** » Fri Nov 28, 2014 9:39 am

One more thing, you can/should spend a lot of time making sure that every weld joint fits perfectly. No step or mis-match allowed. I use a simple pipe expander to gently expand the smaller pipe or to make a slightly oval cross-section round. Even though you will be using mandrel bends the cross-section in the bend is smaller (slightly) than the straight section so you need to bump them a little at the joint.

900HP · Post by **900HP** » Fri Nov 28, 2014 9:47 am

Here is a set I'm working on right now for a 409 in a 55 Chevy with a 4-speed and rack&pinion steering. I didn't install the stupid ass rack either. Also, the customer was concerned that they "look correct side to side" so compromises that were made on the left side because of the rack were carried over to the right side so they looked somewhat symmetrical.

409 Chev headers 2.jpg

409 Chev headers 5.jpg

409 Chev headers 6.jpg

409 Chev headers 4.jpg

1972ho · Post by **1972ho** » Fri Nov 28, 2014 10:13 am

Wow good looking header,And long to why are they so long for looks are performance .

77cruiser · Post by **77cruiser** » Fri Nov 28, 2014 10:13 am

I know who that's for.

bigfoot · Post by **bigfoot** » Fri Nov 28, 2014 10:19 am

Dies headers by Ed sell flanges to bolt onto head ?? I have dart jr heads on a sb ford..it has to bolt patterns..my headers use the inside bolts...so the headers pinch off the sides of my ports..i guess this hurts the flow ??

900HP · Post by **900HP** » Fri Nov 28, 2014 10:35 am

1972ho wrote:Wow good looking header,And long to why are they so long for looks are performance .

The header pictured is 32" (+/- 1/2") on tubes 4,6,8. Tube #2 is 37" (this was a compromise to make it look similar to the left side).

I don't think that's out of line for a street car header that will operate mostly at part throttle cruise type applications.

The other side is quite a bit more different with 2 tubes at 31-32", one at 35" and one at 38". It's what I had to do to make it fit and look half decent.

900HP · Post by **900HP** » Fri Nov 28, 2014 10:35 am

bigfoot wrote:Dies headers by Ed sell flanges to bolt onto head ?? I have dart jr heads on a sb ford..it has to bolt patterns..my headers use the inside bolts...so the headers pinch off the sides of my ports..i guess this hurts the flow ??

Check with SPD exhaust

900HP · Post by **900HP** » Fri Nov 28, 2014 10:37 am

77cruiser wrote:I know who that's for.

LOL. call me if you have any questions, I'll help if I can. I still have a lot to learn so I'm by no means the end-all be-all.

jacksoni · Post by **jacksoni** » Fri Nov 28, 2014 11:20 am

These guys have a lot of parts and flanges and a good video series about building your own. On the website and youtube both. http://www.stainlessheaders.com/index.aspx

MadBill · Post by **MadBill** » Fri Nov 28, 2014 6:40 pm

77cruiser wrote:I'm going give it a shot. How many hours can be expected for a first timer?
I'm thinking at minimum 100 hrs.

My first (and last) time 30 years ago took me 160 hours, but I built the flat collectors from sheet metal and made oval section megs by splitting round tubes and welding in tapered flat stock, which I then bent and twisted around the cross member before realizing that it would have been far easier to build the megs straight and do all the tweaking on the transmission support.

77cruiser · Post by **77cruiser** » Fri Nov 28, 2014 8:32 pm

I should've said more like 100-200 hrs. I gonna try to keep track, so if someone asks.

lada ok · Post by **lada ok** » Fri Nov 28, 2014 9:03 pm

If at all possible you want the flanges to be counter bored 3 mm to take the pipe o/d or bored right through, then the pipe slips into the flange and is welded at the back side..... no mess and looks rea factory

There are header pipe kits that have allow you to run up a dummy set so you can check out what's what
Or go to your local plumbing merchant and you should be able to buy PVC plastic pipe and elbows to play around with
Wouldn't worry if each pipe isn't exactly the same length
Think about just tack welding the thing up, then take it to someone that can TIG weld ... you can use an old head as a jig one end & known distances at the other

Don Terrill’s Speed-Talk

First time header build

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