Does anybody know how to fit tube this way?

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I found this pic on the net searching for turbo header collector. I was wondering if anybody here knows how to fit tube like this, and if so let me know. I need to build a collector, and i need good fitment to keep it from cracking under the extreme heat and pressure of a turbo manifold. Attached ImagesMiller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:Looks to me like they may have ben layed on there side and cut with a hole saw then put togather. Looks like time to experiment.Good LuckH2osStickers.comMiller Syncrowave 250 Hi-FreqMiller 252 migHypertherm Powermax105Miller Maxstar 200Hypertherm 1650Tourchmate 1   4' X 8'Hossfeld Bender30W Laser Engraver
Reply:its pretty simple, its just 4 tubes cut like that. the trick is to pratcice on PVC pipe till you get the angles down.
Reply:Holy **** That Looks Hard!KISS...KEEP IT SAFE STUPID
Reply:I Think It Could Be Done With A Bandsaw And Alot Of Patience>KISS...KEEP IT SAFE STUPID
Reply:I've done quite a few of these. It can be done with a chop saw, if you can clamp it down and get the correct angle. It does take some practice to get the correct angle of the cut and to get them to mate up. A bandsaw is easier to make these extreme angles or bologna cuts. Even with a bandsaw, it's tough to hold the material, follow the line and get a good cut. Again, practice before making a final piece. Draw your lines with black, red or another color Sharpee...then, make your cuts. Here is a picture of a big dual 3" to single 4" merge collector I recently made: John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:I need to pigure out how to make one like the pic I posted, all symetrical, and tight fitting, so I can make a cutting jig for the plasma cutter. I know that once I make one, Im going to have people asking for them, so I figure I should make it possible to replicate easily. I have been trying to mock it up with cardboard tube, but I think the PVC idea will be more realistic since it wont flex as easily.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:nice microzone!
Reply:To experiment with tubing cutting/angles...Save the cardboard tubes that are available in gazillions of paper towels and use them for mock-up..Damn!!!Another secret...  Nice job John!! ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Pretty interesting the way it comes togetherLooks like it could have been done with a tubing notcher ..Perhaps two seperate cuts with a nothcher?Washman
Reply:Thanks fellas! Use cardboard, PVC, whatever is the cheapest.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Funny you say that Zap, this is what Ive done so far. Attached ImagesMiller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:Twisted minds......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Getting close, think of it as a square and then cut out "two sides".John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Right, two cuts, each pipe done at a certain degree.  Very slick.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:Copied from another forum:"Seeing as how most people here are V8 and 4 cylinder guys, it’s a pinch of **** to make your own merge collector. Just get 2 pieces of pipe, cut the exact same bevel off each one, and then weld them together. Do the same with another 2 pipes, so you now have 2 pairs of V shaped pipes. You want to take half of the outlet diameter off the pipe, so when you weld the 2 halves back together, you get a circle again. Then cut/grind the same bevel off these 2 pairs of V's so that they can lie against each other just like the first 2 did. There you have it, your very own merge collector. IF you have a Milling machine this process will be far easier. I still find it easier to do the first pair of V pipes with a drop saw and just use the mill do machine these welded together. If you have a V8, you will need 2 sets of these obviously."
Reply:Just buy a tubeing notcher from harbor frieght. They work very well, I have one and I have no complaints.  I have built gates, roll cages, railings and towers for boats and every thing else.  Just get the correct hole saw, and you will perfect fishmouth joints  I Bolt the jig into a vise and use whatever drill that fits your needs or budget. I like to use my DeWalt Cordless 18volt.Mike
Reply:Check this out-http://www.turbomustangs.com/smf/ind...?topic=65147.0Its a tutorial on how to make merge pipes using food coloring and water, worked pretty good for him
Reply:I am no expert at anything like this, but I can offer a couple of suggestions.First, a tubing notcher is not going to help at all.  Those are all straight cuts.Second, if it is truly symetrical, (sp?), there are 3 different cuts.  Eight are all the same cut, just lefts and rights. 4 one way and 4 the opposite way. Then there are the 4 end cuts, but again they are all the same.It would seem that you could make up a Jig to hold the proper angles and then either whack them off in a chop saw, or run them through a band saw.I made up a sketch to show you, but don't know how to post it in here.  If you like, I can send it to you directly if you send me a PMBob
Reply:I am going to try and make one of these for fun. Will try to take pictures and post how I make out.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:That is correct, a tube notcher will make rounded cuts, these need to be mostly flat. You also have to calculate your finished diameter - cut too much and it's too small, cut too little and it's too big to fit the application.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Frederic over on FTE was making some, might be worth a look;http://www.ford-trucks.com/forums/46...ighlight=turbo
Reply:Only read the first page but some very ingenuousness stuff going on there! Yes, that's a word and derivative of ingenuity.  This is the only time I can use that word, so I took advantage of it. Very cool how he is doing the budget build using black pipe. Very cheap and probably effective. I've been a member of the blow-thru Yahoo groups for 7 years and have seen some neat stuff come through there. Travis, from Hanger18 Fab, knows his stuff. He's also a member there. Thanks for sharing the link.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:get a bucket of water, blue food coloring, a sharpie, and towelhttp://www.turbomustangs.com/smf/ind...?topic=65147.0woot, my first usefulness
Reply:headers by ed.  he has a cd that will tell you how and mandrel bends, etc.Thermal Arc 185 TigHTP 200 MigCraftsman O/A1942 Bridgeport Mill12 Ton Hyd PressConsew Walking FootAwesome help guys, Im now confident that I can do it. The food coloring method makes very good sense. The properties of a liquid are an awesome tool for get straight lines on tube. I should have thought of that.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:That's a great idea, but I think I would add a twist to it. If you colored the water, or used some dye or paint instead, and wrapped the tube in paper before you dipped it you could then unwrap the paper and cut out the pattern. Then you could just wrap your pattern around the tubes and trace around the paper.Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:Originally Posted by Joe HThat's a great idea, but I think I would add a twist to it. If you colored the water, or used some dye or paint instead, and wrapped the tube in paper before you dipped it you could then unwrap the paper and cut out the pattern. Then you could just wrap your pattern around the tubes and trace around the paper.
Reply:Originally Posted by LSX89RSget a bucket of water, blue food coloring, a sharpie, and towelhttp://www.turbomustangs.com/smf/ind...?topic=65147.0woot, my first usefulness
Reply:Originally Posted by MicroZoneOnly read the first page but some very ingenuousness stuff going on there! Yes, that's a word and derivative of ingenuity.  This is the only time I can use that word, so I took advantage of it. Very cool how he is doing the budget build using black pipe. Very cheap and probably effective. I've been a member of the blow-thru Yahoo groups for 7 years and have seen some neat stuff come through there. Travis, from Hanger18 Fab, knows his stuff. He's also a member there. Thanks for sharing the link.
Reply:Nope, as an adjective, it means free from reserve, restraint. I probably incorrectly used it as a noun, instead of an adjective. Dang ! John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:in·gen·u·ous adj.in·genu·ous·ly adv.in·genu·ous·ness n.Actually, you used the noun where you should have used the adjective.....But.....I really wasn't going to say anything.....really  Patrick
Reply:Uh huh, that's what I say in the post above. Thanks for correcting my grammer but maybe read the entire post.  Now, can we get back to welding criticisms? John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by zapsterTo experiment with tubing cutting/angles...Save the cardboard tubes that are available in gazillions of paper towels and use them for mock-up..Damn!!!Another secret...  Nice job John!! ...zap!
Reply:The food coloring and water idea is a good one but I would try to do it a little differently.After coloring the pipe, I would clamp it to a fixed object at the desired angle.  Then I would place the bucket of water on something that I could slowly raise until the water level met the centerline of pipe marks.  I think you could rig up some sort of flat surface to a floor jack to support the bucket (the bucket wouldn't have to be exactly level because the water would remain level regardless).This should result in less of a trial and error process and should also be a bit more precise.
Reply:One question - in the originally posted photo, it looks like it wouldn't be too hard to shape the cuts so that the pipes could also be welded from the inside.  Does anyone ever do this to get a nice strong weld and a good seal?
Reply:Is it my imagination or is the bottom hole smaller than the top radius of that original pipe?
Reply:Irish - yes, some are welded internally and then ported or ground down. Johnny - not sure what you mean...which picture?John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:There's a pretty good reason to keep the "old" heads around.
Reply:1) Cut four 2" lengths of tube with an ID slightly larger than the OD of the primaries. (snug fit)2) Tack these into a square shape.3) Fill the center with a diamond shape of sheet metal and weld in place.4) Roll a cone, one end has an ID to fit over the square you just made. the other end has an OD to fit the secondary.5) Place the square of tube lengths(#2, 3) inside the large end of the cone, place on a mandrel and heat and hammerform the cone to conform to the shape of the tube segments.  Tack as you form each side.6) Once its all done weld it up.7) The primaries slide into the four tube segments and dump into a single piece unobstucted collector with only a single seam down its length.
Reply:Just like legs on a barstool, made by left and right-handed compound cuts.
Reply:Originally Posted by zapsterTo experiment with tubing cutting/angles...Save the cardboard tubes that are available in gazillions of paper towels and use them for mock-up..Damn!!!Another secret...  Nice job John!! ...zap!
Reply:Originally Posted by zapster Twisted minds......zap!
Reply:The simplist way to cut that tubing is with a off set tubing notcher I have a JD2 tubing notcher you can adjust the amount of offset you want to cut out.I purchased it from Van Sant Trick tools 249.00 it's pretty trick uses hole saws.
Reply:I rather use a grinder with a cut wheel....I´m sure I can make better cuts with it than with a hole saw or a bandsaw I´ve learn so much about it  it´s like my 4rth leg  lololMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:The tubing in the first pic is definitely notched.  Look at the shape of the joins carefully and the angle of the edges where they meet.  It is made with four identical notched pieces of tubing with two notches cut in each piece.  Like a mitre joint, any angle on the notches, as long as they are identical, will produce mating joints.  The issue will be the angle at which the tubing "departs" and the angle at which the joints mate.  I'm sure there's a way to calculate the notch depths for a given angle, but my geometry class was too many years ago.    This will do it in short time:http://www.mittlerbros.com/Tube_Notcher_Ultimate.htm
Reply:Originally Posted by phila.renewalThe tubing in the first pic is definitely notched.  Look at the shape of the joins carefully and the angle of the edges where they meet.  It is made with four identical notched pieces of tubing with two notches cut in each piece.  Like a mitre joint, any angle on the notches, as long as they are identical, will produce mating joints.
Reply:Originally Posted by CapnbondoAre you sure? It seems to me more like they were cut on a bandsaw or chopsaw or etc and the cuts are straight, not notches.
Reply:Can I assume that there are actually some visible lines (for someone at least) on the pipe using the food coloring?  I can't see any in the images on that site.-- Sandy
Reply:QUCIFER,i sent you an e-mail, hope you got. i lined up the way i woulddo this part. i tried to post a reply, but it did not go. hope thisone does.wlbrown