still_alive
08-14-2011, 06:43 PM
Well since you can't find them anywhere, and if you can they're not cheap, I decided to make my own and I'm pretty happy with the results.
Materials:
2- 2x4's
8- 5/16" Hex head lag bolts with washers to hold the header down on your jig
1- 6" radius, U shaped 1 5/8" mandrel bent pipe= $16
1- 4" radius, U shaped 1 5/8" mandrel bent pipe=$16
Grinding wheel w/ cut off wheel
*Tail pipe expander=$8 just to keep the pipe's shape
Welder and skills :grin:
First, I designed the 2x4 jig around the header and added some good bracing so that the flanges didn't shift while I was cutting and welding on the pipes.
https://sl-i.net/FORUM/images/imported/2011/08/img0734w-1.jpg (http://imageshack.us/photo/my-images/803/img0734w.jpg/)
Then I cut the y-pipe in half and cut the pipe off the flange about an inch up so I had room to weld. You then have to flip that elbow 180 degrees and weld it on and make a 90 degree turn that starts heading towards the other stock pipe. From the front of the pipe on the flange to the front of the pipe that heads towards the front of the car measured 8 ½”, that's so you don't run into the radiator but also clear the oil filter. I re-used some of the old piping for the bends. When you start trying to piece it together and meet the pipes up remember to only tack weld until you get the whole header put together otherwise it's a pain in the ass to take apart if it does match up, plus you waste pipe. You're going to want to hug the stock pipe as close as you can, but if anything, make the UEL pipe hang a little low, as in away from the engine. Once you have tacked everything in place and it seems to fit well, fully weld in all the joints while it's still on the jig so that the heat from welding doesn't warp the header.
https://sl-i.net/FORUM/images/imported/2011/08/img2011081300024-1.jpg (http://imageshack.us/photo/my-images/694/img2011081300024.jpg/)
Now you can stand back and marvel at your work and think about how much money you saved!
Total Cost : Around $70.00 Total Time: About 5 hours
It's up to you if you want to paint it or wrap it, or both…I am going to paint mine for now so I can make sure none of my welds leak, then probably wrap it later on.
https://sl-i.net/FORUM/images/imported/2011/08/img2011081400031-1.jpg (http://imageshack.us/photo/my-images/220/img2011081400031.jpg/)
Good Luck and if you have any questions, feel free to ask.
By: still_alive
Materials:
2- 2x4's
8- 5/16" Hex head lag bolts with washers to hold the header down on your jig
1- 6" radius, U shaped 1 5/8" mandrel bent pipe= $16
1- 4" radius, U shaped 1 5/8" mandrel bent pipe=$16
Grinding wheel w/ cut off wheel
*Tail pipe expander=$8 just to keep the pipe's shape
Welder and skills :grin:
First, I designed the 2x4 jig around the header and added some good bracing so that the flanges didn't shift while I was cutting and welding on the pipes.
https://sl-i.net/FORUM/images/imported/2011/08/img0734w-1.jpg (http://imageshack.us/photo/my-images/803/img0734w.jpg/)
Then I cut the y-pipe in half and cut the pipe off the flange about an inch up so I had room to weld. You then have to flip that elbow 180 degrees and weld it on and make a 90 degree turn that starts heading towards the other stock pipe. From the front of the pipe on the flange to the front of the pipe that heads towards the front of the car measured 8 ½”, that's so you don't run into the radiator but also clear the oil filter. I re-used some of the old piping for the bends. When you start trying to piece it together and meet the pipes up remember to only tack weld until you get the whole header put together otherwise it's a pain in the ass to take apart if it does match up, plus you waste pipe. You're going to want to hug the stock pipe as close as you can, but if anything, make the UEL pipe hang a little low, as in away from the engine. Once you have tacked everything in place and it seems to fit well, fully weld in all the joints while it's still on the jig so that the heat from welding doesn't warp the header.
https://sl-i.net/FORUM/images/imported/2011/08/img2011081300024-1.jpg (http://imageshack.us/photo/my-images/694/img2011081300024.jpg/)
Now you can stand back and marvel at your work and think about how much money you saved!
Total Cost : Around $70.00 Total Time: About 5 hours
It's up to you if you want to paint it or wrap it, or both…I am going to paint mine for now so I can make sure none of my welds leak, then probably wrap it later on.
https://sl-i.net/FORUM/images/imported/2011/08/img2011081400031-1.jpg (http://imageshack.us/photo/my-images/220/img2011081400031.jpg/)
Good Luck and if you have any questions, feel free to ask.
By: still_alive