Latest Project - Headers

[Miguel Antonett]

Do you still have the Fuchs on it? If so, that'll match - sort of...

[911st]

Originally Posted by RarlyL8

Yes, it is convergent evolution.

Brian,

I drew up the what was basically the same design about 6 years ago but did not have the energy , resources, nor abilities you do so it never got further than an idea. I am good at ideas, but that dose not count for...

That is why I instantly guessed / recognized that you were doing from just seeing your picture of the one first header/collector mock up.

I thought that if one could come up w a one header design (as you have) that can be bolted up to ether motor side and then joined up with equal length tubes to the turbo, you would have a near perfect set up considering the 911 motor layout. Further with only one header design to produce you have simplified construction and production.

First rate!

[RarlyL8]

Yes that is the idea. The exhaust flanges of the 911/930 are asymmetrical which further facilitates the use of identical headers for each bank. That design allows you to cut cost in half without any compromise in performance or ergonomics.
My goal is to create a far superior design (equal length primaries, equal length secondaries, merge collectors, 321 construction) than the current competition that can sell for about the same price. All while also being made in the USA.
Lofty goal but I think we can do it.

[911st]

Most excellent!

[RarlyL8]

Well the tooling for each header is finished. I received a very large bill today that made me sit down and breath hard for a bit. Looks like I'll need to sell quite a few sets of these puppies before pay back on the investment. Not all that unexpected but never pleasant.

Here is what we have now. The merge collector has spring tension expansion joints. I will begin making the secondaries this weekend using my car. The plan is to allow use/retention of the stock oil lines for a savings of $230. Try as I may I cannot design around the factory turbo oil tank. The early USA tank is OK and the early Euro is OK but the late USA tank fits right where the right bank must merge. Dammitohell I tried.

Final product will have a brushed finish like my mufflers and look MUCH better than the Beta unit pictured below. Secondary will place the turbo in the stock spot and the waste gate very close to the stock spot. Emphasis is on fitment.

Looks like we will go to production in a few weeks. I need to sell several sets of these and get some feedback before putting them on Pelican, so please contact me if you are in the market. I will be taking deposits for serious buyers. Price point in 321 stainless with equal length primaries, secondaries and merge collectors is ~$2K+. Price will likely go up after the initial run due to the costs involved.

[spence88mph]

Originally Posted by 911st

Brian,

I drew up the what was basically the same design about 6 years ago but did not have the energy , resources, nor abilities you do so it never got further than an idea. I am good at ideas, but that dose not count for...

That is why I instantly guessed / recognized that you were doing from just seeing your picture of the one first header/collector mock up.

I thought that if one could come up w a one header design (as you have) that can be bolted up to ether motor side and then joined up with equal length tubes to the turbo, you would have a near perfect set up considering the 911 motor layout. Further with only one header design to produce you have simplified construction and production.

First rate!

the same header part on both banks?!! whoa, this is an amazing idea, especially since it's what Porsche did on their standard production 930s, SCs and Carreras... Maybe you could also come up with some kind of sprung bar instead of springs.

Sorry couldn't resist.

Looking good BTW Brian, are you planning on a heat solution?

[RarlyL8]

Yes, heat exchangers will be added in the future. They will bolt on so can retrofit the headers in the field and also replace or repair if damaged by road debris.

[RarlyL8]

Lastest number crunching looks like we can meet the sub-$2000 price point if building in quantity.
I'll post more pictures as the secondary Y-pipe comes together. Can't wait to get this to the dyno and see how much torque will be picked up off-boost!

[kenikh]

True equal length headers are a big benefit to anyone wanting to use a twin scroll like a Garrett, since you need to ensure that the exhaust pulses are perfectly, evenly spaced. Computer modeling and CNC mandrel bending are the ultimate solution to ensuring zero variance (the 1.5% question) on the pulse coalescence for these applications. Did you build these manually or did you model them on a computer?

I personally prefer headers that are mirror images of each other as it makes fabbing pipes after the headers easier for us garage fabrication hacks. Regardless, these are sick...after I get my engine up and running on my Narbel headers, I might need a set of these if I don't like the dynamics of the longer tube primaries. We'll see!

Great work and keep us posted!

[Miguel Antonett]

Brian, do you think it will be a straight forward DIY installation? By looking at the picture, it appears that a couple, or may be three, of the flange nut/studs are blocked by the primary to use a common "straight" wrench extension - it could be the shot angle... Regardless, let me know when they're available.

[krasuskyp]

FWlittleIW...

I had the outright *pleasure* of fooooooooondling these at the commencement of turboPALOOZA a coupla weeks back. Brian was nice enough to give me a sneakpeak when I dropped him off @ his Fuchmobile.

While in pics they look gorgeous - pics are _nothing_ compared to seeing them in person. Works of artisanship and the highest degree of craftsmanship are understatements.

SEXXAAAAY!

I'm rather f'n pissed I'm in nooooo position to jump in here, as, this is quite the great opp. Ah well, some day.

Brian, best of luck to you in getting this launched. You have served our community so well with your exhausts (you should hear alllllll the compliments I keeeeep getting on mine!)... and have truly outdone yourself here with these.

Rock on.

[mb911]

Originally Posted by kenikh

True equal length headers are a big benefit to anyone wanting to use a twin scroll like a Garrett, since you need to ensure that the exhaust pulses are perfectly, evenly spaced. Computer modeling and CNC mandrel bending are the ultimate solution to ensuring zero variance (the 1.5% question) on the pulse coalescence for these applications. Did you build these manually or did you model them on a computer?

I personally prefer headers that are mirror images of each other as it makes fabbing pipes after the headers easier for us garage fabrication hacks. Regardless, these are sick...after I get my engine up and running on my Narbel headers, I might need a set of these if I don't like the dynamics of the longer tube primaries. We'll see!

Great work and keep us posted!

these are mirrored for the NA application Brian I don't have any pictures on this computer do you?

[RarlyL8]

Thanks for the props; been sitting on this header design for a long time and so glad to be doing it now. I think once you see the complete finished product the dual right hand design will make more sense as it allows for equal length secondary pipes.
I have not mensioned the normally aspirated version of these headers on this board. Stayed the course of everything 930. But yes there is a mirrored version that will be used on the 911. I can post some pix later. That system will be completed after the 930 system and will be less expensive 304 stainless. We will also offer thick-walled 304 stainless for the 930 as a base product with best pricing. Similar durabiltiy but more weight than the 321 which has a constituent of Ti.

[Noah930]

Brian,

Tried to send you a PM, but your box is full. What are your plans for fitment of the turbo oil tank on later cars? Are your headers going to require relocating the tank? If so, what are the options for relocation?

[WinRice]

Damn the oil tank and full steam ahead!

All kidding aside, those are nice looking! That oil tank seems to get in the way of several nice mods. What we need is a nicely engineered, well thoughtout oil tank relocation kit taylored to the 930, similar to a 965 or 993 setup (hint, hint!)

[RarlyL8]

Most likely we will end up making our own oil tank. I would like to revise those small cylindrical tanks commonly used to include a breather outlet like the stock tank has. It also needs to tuck up to the engine better as I know of a few folks who have busted them off hitting things in the road. Can you imagine doing that at freeway speed!!!!

Here is a picture of the mirrored headers for the 911.

[kenikh]

Now all they need are v-band flanges!

[turbobrat930]

Originally Posted by kenikh

Now all they need are v-band flanges!

Just wait.... a set is in the works...but I will let Brian tell you about those!!!!!!

[RarlyL8]

Yes, Brad will be getting a very exotic set of headers with 1 5/8" primaries, dual waste gates, v-band flanges and a v-band turbo mount for the TiAL S/S beauty. I'll let him show pictures of that creation when finished.

[Thierry25]

Originally Posted by RarlyL8

Here is a picture of the mirrored headers for the 911.

Very nice job ! Congratulation !

By the way, as you tested many kinds of things for exhaust , have you ever try header and exhaust heat insulation wrapping ? Do you have any opinion about it ?