Thread: making headers

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I have a super tight engine to frame situation and I haven't been able to find anyone who has headers that will fit (hedman, sanderson, etc). I'm running out of options, and I refuse to put cast manifolds on my truck. I think I have to make my own headers.
Does anyone have suggestions on this issue?

Making a complete set of headers is quite possible, but its a lot of pain to go through (I've done it)---hardest part is the money you have to pay after all the welding is done to have the flange faces machined flat, to seal against the block. I strongly advise that you buy something close to what you want in a plain uncoated header, and modify only the pipes that you have to, staying a couple of inches away from the flanges that mount to the block, so that they don't move around on ya.

How about Hedmans shorties for S-Truck V-8 conversions. They exit fairly high and to the rear. I have used them on other swaps besides the original intented use.

When i was younger I used to make headers all the time. Then I bought a big truckload of "seconds" and just plain DNF headers from a famous header manufacturer. It sure made things a lot easier. By modifying a couple of tubes. Instead of making up everything from the flanges to the collectors.

I have a set of full headers, they don't even come close to fitting though. I know making them will be a tremendous amount of work. Getting the flanges machined won't be a problem because my dad runs a machine shop, it's just the rest of the job I have to worry about.
Here's a pic of the bad side(with the starter), I think the other side is fine, it's tight, but not that bad. I didn't think the passenger side was too bad either until this weekend when I put the starter in place.
Hedman told me they had nothing for me.
Since I do have a set of full headers that don't fit, what would you guys recommend I do first? The thing is, I can't even begin to get those things in place. Should I start cutting off the outside pipes until I can at least fit them in place?

Yep---Fire up the torch and start cutting, untill you can at least get the flange (or flanges) bolted to the heads. Be sure to install the proper gaskets (you only want to modify these things once).
--better yet, do your cuts with a cut off wheel or hacksaw, as square to the pipe as you can eyeball it--that way you may be able to just rotate sections of primary tubes and then reweld them back in place.---get as much weld on as you can with everything still bolted up, then let them cool untill they are stone cold before unbolting them and finishing off the welds in the areas that you couldn't get to.

I'm gonna get out the old hack saw right now.
thanks

Originally posted by tcodi
I'm gonna get out the old hack saw right now.
thanks

you ant put that clutch linkage on that left side yet.

yeah I know, I gotta get that thing in there before i can do the driver side.
The real bad side is the pass. side though, with the starter. I just got that one cut up and mounted, now I can see where I need to put the tubes.

Hooker makes quite a few conversion headers for things like v8's in s10s and such. Helps if you tell us what kind of vehicle this is.

it's a 1950 chevy truck with a big block in it.

I don't have any part of the steering likage set up, except for the rack that's in place.
should I just use sticks or something to mock up some sort of linkage for that before messing with the headers?

How wide is your frame at the starter location, (inside to inside) , the reason I ask is with my 38 chevy frame and 454 engine i was able to use standard headers from a 70-74 Camaro/Elcomino without any mods at all on the passenger side. Diver side I hade to move two pipes to make room for steering shaft. I think your application should be similar.

paul

in between the starter and frame I have a little less than 3 inches. I cut some full headers I had last night and got the pass side mounted. After mounting them I could tell that there is no way they would EVER have gotten in there without being cut. I'll have to modify just about every tube. I take a picture of what it looks like when I get home today.

after cutting

Originally posted by tcodi
after cutting

go to the out side of the frame.