[SuperB70]

Lets continue. Even it looks like I don't get conversation going here.. go figure..

Last I showed how I made my collectors, is't time to build stainless headers.

Idea was to design those build blocks ( again, buying set and importing it here is way too expensive) But I found file from Grabcad that was right radius for me. So I started printing those out of PLA, no need any exotic material here. To make one set of shorties.

Next I draw and printed fixture to cut tubes in my band saw. Glued pieces of bicycle inner tube in it. Now it clamps much tighter.

I draw up a flance of ex side of the cylinder head. Made it so that every primeries has own, not all bridged together.

Made program to our vertical mill with Heidenhain.
Side note: If here are any machinist, if you look that picture, do you catch the great idea there?
I'll point it out: Table has upright 90 degree bench on it. There is "waste"plate bolted to that bench. Now you can mill that straight, or make a needed groove, an edge, or like me here, welded piece of axle and mill that to fixture for the flances. I can mill 1mm deeper and dont have to worry about hitting the expensive and hard bench. After I'm done, just cut the piece off and mill the surface flat again. You can see the groove there at the bottom, I used it to get my supercharger intake flance bolted vertical to it when I milled it to square and flat.

First I milled aluminium ones, with M6 threaded hole, to bolt first build block on them. Then chanced material to 10mm stainless and made real flances, with little recess around the port hole. For the tube to sunk, much better to weld.

Bolted aluminium ones to cylinder head and started to build primeries. So of my printed block broke right away or where loose so I secured the rotation with electric tape. What ever works/goes
Sorry about low quality picture, had to dig it out of old garage camera.

When all "tubes" where made, made sure that all had space to grow, connected to collector (witch was hold in its place with small made fixture witch was bolded to frame tube with coulpe hose clamps.) was time start transfer shapes to stainless. Cut and tack, 3 tacks to every joint.

I am as always critical about my welds (could be better), header came out "ok". I have stainless weld seam cleaning machine, all welds will be cleaned. Color is actually bad. My dry sump pump fit under it ( maybe, mounting system is still ongoing prosess in my head.

Then it was time to test fit the sleeves that I made with shop press. When using slide fit collectors those are good to use, reduse air leaking witch lambda don't like. Smaller end slide over the tube, it will be welded and bigger end goes over collector. Then little eyelets for spring to hold everything together.

Then I did the driver side, wanted them to look alike, even its not 100% possible for many reasons. One thing left to do is weld bungs for K-sensor (exhaust gas temperature) to every primeries. With that, again I run it to no space needed situation. Have room underside but tip of the sensor should be at main flow of the exhaust and that is on top of the tube, gases comes out on top of the exhaust port.. Really dont want to expose so much of the sensor. Would lead to premature sensor failure. Have to think solution..

Been thinking about stainless/ceramic wrap (dont like the look)or spray/powder ceramic coating on them. They will color up nicelly but heat control in mind.

Who's gonna guess what im going to show next?