Headers!

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I recently got a PO to build some headers for a local race car manufacturer that builds several different spec racers.  I was given a rough prototype set and some jigs along with all the mandrel bends and required materials.  The collectors are premade by Hedman - and fairly rough with big mig welds and gaps in the stops and starts.  I don't have dies for my bender in 1.875 OD, so using U bends was the way to go.Fitting the tube pieces up in the jig:Due to obstructions in the car the headers are installed as 2 halves as you can see by that last pic.Welding up the primary tubes:Welding the primaries into the flange:I found the tubes flopping around on the welding table a royal pain to position, so I used a base from one of my homemade material stands to make a tube holder.  It adjusts up and down, has about 180 degrees of angle sweep, and you can rotate the tubes in the v-clamp as well.  This made welding everything up MUCH easier!And here are some pics of the complete header assembly:One done - 9 more to go!  And, there might be 10 more following this first batch of 10!
Reply:nice work.JImmy
Reply:Awesome. I love headers. Squeezing quality exhaust work into tight spots is one of those jobs that really gives a feeling of satisfaction when you are finished -Ryan
Reply:thanks, for the post!!!  nice work.   It looks like 10 headers may take a few minutes to weld. lol   Daye
Reply:Looking really good...very nice project-Graham-Mechanical EngineerAutosport Mechanic/Fabricator
Reply:Looks good. The HAZ is a little wide for my liking. What size Tungsten? This looks like it's for a import car?John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:I guess I should have mentioned - these are all mild steel - a combination of .049 and .065 wall tubing.  1/16" tungsten, .030 mild steel filler rod.  I don't know the amps; not much.  The thin mild steel changes color really fast - but I wouldn't call the color change area an actual heat affected zone.
Reply:Oh, and it's a header for the "DP02" found here: http://www.elanmotorsports.com/?action=page.products
Reply:Nice stuff, I agree with the thin wall, it's a tough customer. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:ive got a variety of aluminum blocks that make welding odd shaped tubes so much easier, just block it where you need it and go to town.(no, our bender still isnt running)Have we all gone mad?
Reply:[QUOTE=TubularFab;179282]Due to obstructions in the car the headers are installed as 2 halves as you can see by that last pic.And here are some pics of the complete header assembly:Great job, looks good to me. I am not a certified welder like most of you guys, just a auto body man. How are the 2 header half's been held in the collector, are there small brackets and springs keeping them together?MartinI can't cut corners, must be the German in me!!!
Reply:more to do? Wow, that looks exhausting!hehehehLincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:coooolll........... wish i could do that!
Reply:looks good to me,nice job ChuckASME Pressure Vessel welder
Reply:Freekin awesome.  You don't need a positioner,  you just built one.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Super job! MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:great job..this is this kind of stuff i plan to be doing after i finish my welding course
Reply:Damn, that is nice!  I just learned how to Tig weld to do something like this.  I just need to find a project to attempt it.  It looks fairly straight forward, but I am sure it looks a lot harder than it seems.  Is there any type of calculations in making the header?  I know it is equal length, but was there any rule of thumb to try and squeeze out horsepower / torque from specific length or size tubing?Wish I can do that.