build your own !
 

wanted to share my latest project. Custom built headers for my 3.6 transplant project (going in my 82' SC). They are 1 3/4" stainless-304, 0.065 ga., equal length, well almost, 18",19",18". Any Thoughts? http://forums.pelicanparts.com/uploa...1257307142.jpg

http://forums.pelicanparts.com/uploa...1257307206.jpg

http://forums.pelicanparts.com/uploa...1257307226.jpg

http://forums.pelicanparts.com/uploa...1257307303.jpg

Nice work!

Any details on the little tube fixtures? I assume you're back purging while welding correct?

Again, nice work.

Tim K

Saawwweeeett!

you sir , have skills , there are many here who would pay dearly for those , they are a work of art , almost a shame to put on the bottom of a motor ....

one idea is to carry a couple of mirrors and put them down when you park to show off your work ... truly nice .

Nice!

"Build my own?" Yeah, right. I would have better luck doing my own open heart surgery.

Fantastic!!:)
Do you have a picture of the complete system?

sensational, man I want to learn how to weld, I have no idea where to start...

great work!!!

Hard to see the clearances in the pics, but could you sharpen the bend in the middle pipe and move it down enough to take an inch off where it meets the head?

You'' probably need a bigger flange where the exit the heads - but excellent work there my friend. How much?

Very nice!

What muffler are you using?

Is it a straight through?

Hoping it is not an X flow muffler.

looks good, what is the orange tube? looks like a really nice way to mock up exhaust.

Holy..... :eek: Nice work!

Your primary tube design is similar to mine. Back purge is not as critical in a non-turbo application but you would not want to suck in any slag during decel. I assume you are welding this up.

http://forums.pelicanparts.com/uploa...1257356612.jpg

Very nice work sir !!!

++++1 on more info about those clamps holding the work prior to welding - I've never seen them before, and they look like very usefull little gadgets !!!

John

All,

The "kit" I used was purchased from a company called "icengineworks" it came with dozens of various pieces (different radius & straights) and the welding clamps you see in the pictures. It took me about a week and several attemps before I got them to fit & equal length. The muffler is a Magnafold "X" flow type at about 14" wide. Somebody said the "x" flow may not be good?? and I think I could have gone with something wider (like 20" wide) and thus less loud?? Any suggestions on olive connector or straight flange type after the merge collector??http://forums.pelicanparts.com/uploa...1257386669.jpg
http://forums.pelicanparts.com/uploa...1257386703.jpg
http://forums.pelicanparts.com/uploa...1257386726.jpg

This it my belief or two cents on the X flow. It was not intended to be used with exhaust gasses coming at each other where the tubes cross. It is more intended as a cross over and muffler for a car with a V6/8 where the tubes and gasses are running the same direction.

If you are intent on a Magniflow style muffler there is one that has two straight through tubes. This has been used with one side of the motor going through the upper passage and the other thought the lower tube in and out.

They also make a Camaro muffler that has two 2.25" In's on each end and one 2.5" out on one end.

Your design is perfect for a Flowmaster muffler which is designed with an In and Out on both ends of the can. It is a proven race muffler on a 911 and makes power but can drone with its two tail pipes.

Fix that sump plate, sonny!!!!

just check out

Ice engine works

Probably cheaper to use some mild tube for mock up..

It modeling blocks...Ideally you use sections of off the shelf tubing....

Header Lego....great concept

Where are you going to mount the lambda sensor ? Can the wires be lengthened ?

Regards

Project looks great, good luck.

I think thats the same box timmins uses on his happy crab muffler

I ran one for a while on my car and it gave great power and a great sound - a friend used it when his Vram was remapped and he got 326 bhp running the magnaflow x over pipe thingy on an otherwise standard engine.

any ideas on where to put the Ox sensor? I think the lead is long enough to go anywhere. Do you think The Magnaflow X" is acceptable? Thanks for the comments so far.

Weld a bung at the end of the collector, assure that is at least 20 deg above horizontal. You can install O2 sensors in each bank, I think that is unnecessary, unless you have carbs or are a data collection freak..

Thanks for the info Tim.

Part II
 

Started the other side today. I am alittle concerned that i did'nt move the merge collector forward by 2 3/8" but instead elongated all the primaries. Any thoughts? I have not welded anything up yet, so I am open for suggestions. Thanks.:confused:
http://forums.pelicanparts.com/uploa...1257741160.jpg
http://forums.pelicanparts.com/uploa...1257741191.jpg
http://forums.pelicanparts.com/uploa...1257741220.jpg

Just my two cents:

Having two different primary tube lengths might broaden your power band a little bit. However, as you have a very low overlap cam there really is not any exhaust savaging going on so it will probably not be of any difference. Your largest benefit being to orderly exit of exhaust on each side. However, this might make for more of a trafic jam at your your secondary cross over point.

I still am not a fan of using the X muffler. Exhaust will be coming directly at each other from each side end of the muffler. Would much rather see a Flow master or something like this.

http://area987.com/project964/exhaust/006.jpg

Or this with one side passing through the bottom and one on the top.

http://forums.pelicanparts.com/uploa...1198447222.jpg

http://forums.pelicanparts.com/uploa...1198447255.jpg

The best.

Thanks 911st for the info, maybe someone would want my brand new magnaflow for a discount?? Well onto fabbing the flanges!!!

I blew 280 hp with my Magnaflow muffler with no restrictions (part # 14386)

http://forums.pelicanparts.com/uploa...1134101951.jpg

have since changed over to 993 headers and an MK exhaust. The Magnaflow is a little loud. You know it's loud when your 10 year old son complains that it's too loud!

Darryl - just noticed the orientation of the 3:1 merge collector - rotating it 60 degrees would put 2 of the pipes "flat" facing the ground, with the third pipe on top. Don't know if this is useful to you re underbody clearance etc.

jcge,
Yes I thought of that too, but it became too difficult to route things that way & get equal lenght-Probably just me just not seeing things right? I must of tried 20 different iterations before I settled on this one. I may have to raise my car however, it's pretty low.:mad:
http://forums.pelicanparts.com/uploa...1258083550.jpg

update
 

Finally got some time to weld ! Well, not the best looking welds but I think they hold-This was my first real attempt at TIG welding. Anyway, any comments on the proximity of the lower tube to the valve cover ?? I am concerned I messed up:mad: I only have about 1" to 1 1/4" clearance at this closest point. Thankshttp://forums.pelicanparts.com/uploa...1264272723.jpg
http://forums.pelicanparts.com/uploa...1264272741.jpg
http://forums.pelicanparts.com/uploa...1264272759.jpg
http://forums.pelicanparts.com/uploa...1264272785.jpg
http://forums.pelicanparts.com/uploa...1264272810.jpg

I'm always amazed by the beauty and design of the 911 engine, not too mention power and sound.
It's a great project you've taken on, I hope you're having fun!

Thanks for the encouragement Dan ! It sure has been one hell of a learning curve!