building custom headers tips

[abadsvt]

Hi guys! I was thinking about building a custom set of headers for my project. I have always wanted to build a set and decided that i should just give it a try. Any tips or a how to would be much appreciated. Is there a specific sequence to weld the primaries to the collectors? I have always wondered how the weld in the middle as the fit the primaries into the collectors. Does that make sence? Also what is the difference between 304 stainless and 409? It is going to be for an LS1 basically stock with a few upgrades but nothing crazy. I was thinking 1 3/4" primaries and 2 1/2" exhaust. Does that sound good? Thanks ahead of time.

Josh

[68protouring454]

once the headers are tacked, you leave collectors off and make a peice to weld in th emiddle of the 4 tubes, you also weld where each tube comes together, so once collector is on there will be no leaks
speedway motors has a 4-1 header kit for 169.99 its 18 ga but well worth the money, you may need a few 45's more however 45 are like 10 bucks each

[B Schein]

I would check out Spd exhaust. I build custom headers in a professional shop we get all our header building material form spd they might be a little more expensive than others but they use high quality steel for all there bends and there bend are done on a very good machine which leaves the tube very round after bending which is a huge factor in fitting tubs together once they have been cut and realigned if the cross-sections are not round it will give even a experienced guy a hard time. Spd makes the little piece that you weld between that four tubes now they call it an (fc) star if you look in the formed collectors section of there catalog you will find it. We build our ls header 1 ¾ primary’s stepped to 1 7/8 with 3 inch collectors.

http://www.spdexhaust.com/

[abadsvt]

Thanks for the replies guys!!! I went to SPD's website and didn't see that piece of metal that you weld on the inside of the tubes? Does anyone have a pic of what that metal looks like or a link to buy that piece? Also is it safe when i tig the headers up to just fuse them together instead of using welding rod as long as I cut the tubes tight toghether or do i need the rod for strength as the metal expands and contracts from the heat? I looked up to see what the factory LS1 has and they have 1 5/8" primaries and 2 1/2" collectors. Should i stay with factory sizes? I was hoping to run 2 1/2" exhaust. Thanks ahead of time!!

Josh

[novanutcase]

Hey Brian!

Is this what you're talking about?



John

[68protouring454]

no use some filler, but get .035 or .045 filler it keeps a strong weld, forgot the scientific explanation of it but you should use filler rod.
also that peice is easy to make, generally 3/4 x1/8 flat bar about a 5.8 piece, then weld the tubes together going towards the outside and inside of the header