Custom Long Tube Header / Exhaust Build ***DYNO Results are In***
03-20-2013, 06:18 PM
#43
11 Second Club
Thread Starter
Progress is slow....but hey, it's progress!
Got the passenger side 3/4 of the way done! Just have the #8 cylinder to finish up, which should be the easiest on the side.
Top view of the big pipes.
Got the passenger side 3/4 of the way done! Just have the #8 cylinder to finish up, which should be the easiest on the side.
Top view of the big pipes.
03-31-2013, 12:04 AM
#46
11 Second Club
Thread Starter
Had to take a break for a few days to take care of some stuff around the house but I've been back at it this weekend. Finished tacking up everything on the passenger side. It looks awesome to see how the final product will look.
The plan is to have the final welding done in two steps. The first step will be to have all of the individual tubes welded up. Once that's done I'll bring them back home to tack them to the collectors and flanges. The reason for doing this is if the tubes move a little bit while welding, I'll be able to adjust them again before welding the collectors and flanges.
The plan is to have the final welding done in two steps. The first step will be to have all of the individual tubes welded up. Once that's done I'll bring them back home to tack them to the collectors and flanges. The reason for doing this is if the tubes move a little bit while welding, I'll be able to adjust them again before welding the collectors and flanges.
03-31-2013, 12:21 AM
#47
11 Second Club
Thread Starter
Now that the passenger side is all done it's time to get crackin on the driver side. I played around with a couple different configurations with the header lego's and decided to go this route. Plenty of room everywhere and fairly easy since there aren't too many bends.
#1- outside bottom
#3- outside top
#5- inside bottom
#7- inside top
Once I figured out how I was going to route everything I got to work on the primaries. I started with #7 since I thought it would have the tightest tolerances and bends. It went together pretty quick.
Now that the #7 pipe is done and the collector is placed the others should be a little easier.
#1- outside bottom
#3- outside top
#5- inside bottom
#7- inside top
Once I figured out how I was going to route everything I got to work on the primaries. I started with #7 since I thought it would have the tightest tolerances and bends. It went together pretty quick.
Now that the #7 pipe is done and the collector is placed the others should be a little easier.
03-31-2013, 05:07 PM
#49
11 Second Club
Thread Starter
Zip ties and my band saw have been working out well. I've found that most of the time getting a perfectly straight cut isn't that important. Having the cut slightly off allows me fine tune the angle by turning the pipe. Sounds ridiculous but I've been using the crooked cuts to my advantage. 
04-04-2013, 08:58 PM
#51
11 Second Club
Thread Starter
5 and 7 are done. Plenty of room around the steering shaft.
I ordered a few 3", 45* bends for the rest of the exhaust along with some V-bands. All 304 stainless to match the headers.
For mufflers I'm most likely going to go with 2 Magnaflow bullets (4"x14") after the X-pipe, then 2 normal Magnaflows in the rear. From what I've read about these, they are on the quiet side, which is what I'm looking for. A pair of cutouts after the bullets can make it loud when I want it loud.
I ordered a few 3", 45* bends for the rest of the exhaust along with some V-bands. All 304 stainless to match the headers.
For mufflers I'm most likely going to go with 2 Magnaflow bullets (4"x14") after the X-pipe, then 2 normal Magnaflows in the rear. From what I've read about these, they are on the quiet side, which is what I'm looking for. A pair of cutouts after the bullets can make it loud when I want it loud.
04-05-2013, 02:55 AM
#52
GREAT work!!!
04-06-2013, 11:55 AM
#54
TECH Enthusiast
iTrader: (15)
Join Date: Aug 2006
Location: DFW....TX
Posts: 624
Likes: 0
Received 0 Likes
on
0 Posts
another quality source for bends is SPD and also Wolf...
Both of them are pricey but produce the best bends out there.
Very nice job on your headers. Any chance you would rent out your header legos when your finished?
Both of them are pricey but produce the best bends out there.
Very nice job on your headers. Any chance you would rent out your header legos when your finished?
04-06-2013, 08:11 PM
#56
11 Second Club
Thread Starter
The bullets are going before the cutouts. I only plan to add additional mufflers after the cutouts so my car can stay under the radar when I need it to.
For now I've just ordered the 2 bullets. Once I get the headers all done I'll hook up the bullets and see how it sounds. If it's not too loud I might just use those. The Magnaflows are supposed to be fairly quiet for a bullet so we'll see.
For now I've just ordered the 2 bullets. Once I get the headers all done I'll hook up the bullets and see how it sounds. If it's not too loud I might just use those. The Magnaflows are supposed to be fairly quiet for a bullet so we'll see.
04-07-2013, 12:11 AM
#57
11 Second Club
Thread Starter
This little project turned out to be much more challenging than I anticipated. Maybe I'm being too meticulous but it takes forever to get all the angles just right. I spent about 10 hours in the garage today finishing up primaries #1 and #3.
First I worked on #1. This one took a while. I had to put an extra bend up near the flange allow enough room for the spark plug.
Here you can see the routing around the steering shaft.
Next I worked on #3. This one had less bends in it but was more difficult due to #1 and the subframe being in the way.
Here you can see that I used 2" radius bends for #5 and #7 to have enough clearance for the steering shaft. #1 and #3 use a 3" radius since they go straight out over the shaft.
Here's my favorite shot!
The next step is to have all the primaries welded up separately. Then I'll tack them to the flanges and collectors while they are on the car. Doing the welding in 2 steps allows me to fine tune the pipes so there's enough clearance everywhere.
First I worked on #1. This one took a while. I had to put an extra bend up near the flange allow enough room for the spark plug.
Here you can see the routing around the steering shaft.
Next I worked on #3. This one had less bends in it but was more difficult due to #1 and the subframe being in the way.
Here you can see that I used 2" radius bends for #5 and #7 to have enough clearance for the steering shaft. #1 and #3 use a 3" radius since they go straight out over the shaft.
Here's my favorite shot!
The next step is to have all the primaries welded up separately. Then I'll tack them to the flanges and collectors while they are on the car. Doing the welding in 2 steps allows me to fine tune the pipes so there's enough clearance everywhere.
04-07-2013, 05:33 PM
#58
11 Second Club
Thread Starter
Today I removed the headers and bolted them up to some junk heads. They look much better outside the car. It's a shame they'll be hidden under the car...
Passenger side
Drivers side
Steering shaft clearance
Spark plug clearance
Passenger side
Drivers side
Steering shaft clearance
Spark plug clearance
