DIY Headers

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DIY Headers

Post  MustangBBF on June 17th 2015, 11:24 am

Ok - Since no one offered to sell me a set I am forced to build custom headers and wanted to reach out for advisement.

I have a 91 Fox body with a 460, AJE frontend, QuickTime 8010 Manual Bell housing with mechanical linkage, stock speedo cable, Hydro boost.

When I had the PG with Kooks 2 1/8 headers they hung to low and would rip the v-bands off the exhaust all the time. Didn't like the PG anyway so switched to a manual for the fun of it.

I have tried many off the shelf headers and they are sitting low or flat out will not clear my configuration. All have been returned except my original SS Kooks long tubes.

Have access to Mig and TIG, bought flanges, and box of bends. Now I'm looking at this mess a little overwhelmed.

I have tried PVC - melting ends and epoxying stub to flanges and trying to run 90, 45, and 22 degree bends.....Never seems to workout correctly. Taken apart and ends are going to be returned to Homeless Depot.

Next attempt is old pool hose mocked in with TIG wire for strength and then filled with spray foam - is this a crazy idea?

Trying to shave some development time here. I am very handy and not afraid of these custom projects but hate wasting loads time on failures.

Not sure what to do next.

Thanks in advance,

Joe

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Re: DIY Headers

Post  bruno on June 17th 2015, 12:52 pm

were are you located ?
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Location

Post  MustangBBF on June 17th 2015, 1:32 pm

Ft. Lauderdale FL.

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Re: DIY Headers

Post  jbozzelle on June 17th 2015, 2:59 pm

I'd modify the Kooks to fit what you have...

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Re: DIY Headers

Post  bruno on June 17th 2015, 3:04 pm

MustangBBF wrote:Ft. Lauderdale FL.


https://www.facebook.com/DanNeumannRaceCarsLLC

or http://innovativeracecraft.com/Contact.html



both of these folks do great work !!!
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Re: DIY Headers

Post  Mustang-junky on June 17th 2015, 10:30 pm

jbozzelle wrote:I'd modify the Kooks to fit what you have...

This makes the most sense to me.

Jess
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Modifying Kook

Post  MustangBBF on June 18th 2015, 11:29 am

There is such a difference in routing between the two bell housings(JW PG and QT 8010) I am remiss to cut up a pair of $1200.00 460 SCJ headers.

I figured a $300 pile of parts is worth a shot in the dark to make a set. Delusions aside this is definitely not a project for the faint of heart as I am finding out.

Maybe I'll picture document my mistakes...errr progress hehehe.

At the very least everyone is helping me achieve the required 25 posts before you can post items to sell.

Thanks!

Joe

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Re: DIY Headers

Post  69F100 on June 18th 2015, 12:09 pm

You are right when building header it is a pain sometimes trying to figure just where you need to cut tube to come out where you want it scratch
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Re: DIY Headers

Post  Race Ready Fabrications on June 18th 2015, 12:41 pm

My best advice if you're determined to build them yourself is to 'Begin with the end in mind.'

Place the collector where you want it to be for best tranny and ground clearance and build to it. I rarely build a header that all 4 tubes on one side are not independent of one another. This will give you a little more freedom as where to place the tubes as well. Also, I'd recommend buying an assortment of large and small radius J-bends.
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Sage advice TY

Post  MustangBBF on June 18th 2015, 2:22 pm

TY - very good advice.

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Re: DIY Headers

Post  1982GT on June 18th 2015, 4:38 pm

I picked up a dynatech header kit from speedwaymotors. It cost around $165 plus shipping, if I remember correctly. The kit even came with flanges. I wish I had better cutting tools while building them,but they turned out ok.

http://s316.photobucket.com/user/z7turbo/library/zephyr%20pics?sort=6&page=4

Above is the link to my build.
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Re: DIY Headers

Post  res0rli9 on June 27th 2015, 12:49 am


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Re: DIY Headers

Post  bonfire on July 17th 2015, 9:00 am

Always thought this looked like a worthshile challenge. anyone ever seen any online tutorials on this process. If not, might I solicit one of you talented fabricators to put your work on youtube

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Re: DIY Headers

Post  MustangBBF on July 17th 2015, 12:01 pm

I am documenting my build. In the next week or two should be able to start posting pictures.

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Re: DIY Headers

Post  bonfire on July 17th 2015, 1:06 pm

Great.... forward to it

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Re: DIY Headers

Post  MustangBBF on July 17th 2015, 1:16 pm

Setting the expectation now: I am a shade tree mechanic. Stuff gets done but don't expect show quality. lol.

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Re: DIY Headers

Post  whatbumper on July 17th 2015, 5:22 pm

All of that is why we get $2000 for our mild steel headers with mufflers. And they are perfect in the end. We have a lot of experience that can not be shared not because we don't want to but because it just takes time to learn it.

we dont use any kind of mock up kits. we place the collector where we want it bolt the flanges on the heads and put a 6" or so piece of hose on the plugs to take up space so you don't make it hard to change plugs. then get after it.

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Re: DIY Headers

Post  richter69 on July 17th 2015, 6:52 pm

^ agree..... Ive always put the flanges on and stuck the collector where it needed to be andgot after it.
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Re: DIY Headers

Post  bowsher21 on July 17th 2015, 8:28 pm

I like to use a standup band saw to cut the tube and you should get a nice 10" or 12" disc sander to face off your tubes after cutting. That will square the faces up for an excellent fit. The better the fit, the better the weld and the better the finished product.
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Re: DIY Headers

Post  bbf-falcon on July 18th 2015, 7:48 am

How would a piece of Flex tubing work to mock up a tube? would this work or no?

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Re: DIY Headers

Post  bowsher21 on July 18th 2015, 8:26 am

bbf-falcon wrote:How would a piece of Flex tubing work to mock up a tube? would this work or no?


There are any number of ways to setup a visual models such as using flex tube. The hard part is transferring it to tube length and angle of cut. I use short sections of 1/8 tig weld wire for distance and angle.
Check this out, If I did more sets of headers I might think about getting this setup.

http://www.jefflilly.com/fabrication/header-fabrication/

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Re: DIY Headers

Post  TommyK on July 18th 2015, 9:35 am


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Re: DIY Headers

Post  jasonf on July 18th 2015, 11:15 pm

bowsher21 wrote:
bbf-falcon wrote:How would a piece of Flex tubing work to mock up a tube? would this work or no?


 There are any number of ways to setup a visual models such as using flex tube. The hard part is transferring it to tube length and angle of cut. I use short sections of 1/8 tig weld wire for distance and angle.
Check this out, If I did more sets of headers I might think about getting this setup.

http://www.jefflilly.com/fabrication/header-fabrication/


That is some pretty bad ass info right there.
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Re: DIY Headers

Post  Super Snake Steve on July 19th 2015, 12:34 pm

i seen somewhere looked like they were using those foam noodles that kids use to float in the pool they had them stuck in the flanges and then bent where they needed them to go and I guess copy that with header tube maybe stick a tig wire in the middle to keep it how you want

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Re: DIY Headers

Post  bonfire on July 19th 2015, 5:22 pm

All great ideas. Like to idea of the 6" pieces of hose to account for plug accessibility. Neat trick. Jeff. Lolly link is awesome and the stainless headers link too. MystangBbf. I still look forward to your effort. Will be nice to see something that isn't professional just so I know I'm not alone in this hobby. In the days of Internet some days I feel like I'm the dopiest untalented auto enthusiast in the nation. Seems like everyone can weld 20 gauge aluminum and make it look like a piece of art. Maybe it's just that those who can't do that don't post pics of their work

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