Ferrari inspired spiral vortex exhaust headers!

linearaudio · Post by **linearaudio** » Sun Nov 16, 2008 6:52 pm

As mentioned briefly a post or two back, I've been experimenting with adapting an MG metro exhaust manifold onto a "Matt" type RC40 system. Having a VERY free run of my local scrapyard,(many thanks Phil & Mike), using one of their scrap Moggys as a jig, I've learnt a fair bit about the various pipe systems used by BL! I wanted something as an alternative to the fabricated manifolds which some say are a bit noisy, (also read about some premature weld failures). After a bit of head scratching and wading through mud & nettles, discovered a mk3 Allegro which has a lovely design of collector box, far nicer than the Metro "crush the pipes together and weld the gaps up" approach. Also has one of those woggly ball jointy bits which should help any minor alignment woes (excuse the pun)! Cut up a couple of old Minor downpipes for the bends and hey presto- one cool looking header! No-you'll have to wait 'til I dress the welds out a bit (tomorrows job) then see it in all its glory!

Post by **bmcecosse** » Sun Nov 16, 2008 7:06 pm

Can't wait! Sounds lovely.

Post by **Matt** » Sun Nov 16, 2008 7:32 pm

onto a "Matt" type RC40 system

you mean a side exit mini system? ;)

linearaudio · Post by **linearaudio** » Mon Nov 17, 2008 7:43 pm

That'll be the one! But with your additions, of course

Post by **Matt** » Mon Nov 17, 2008 9:41 pm

some straight pipe and JLH over axle bend!

linearaudio · Post by **linearaudio** » Tue Nov 18, 2008 4:32 pm

Apologies for the "functional" welding! Hate welding tube. Anyway.....<br>

<br>
Got a bit carried away when I saw a Ferrari header assembly in for repair at the scrappy, a bit of Italian influence rubbed off!! Seriously, it was the only sensible way to get both pipes through the hole in the bulkhead.

Post by **alainmoran** » Tue Nov 18, 2008 5:06 pm

How did you deal with avoiding drips of weld hanging though on the inside of the tube?

I need to make a new exhaust manifold for the V4 in my pickup and working out how to avoid this has been worrying me for a while.

linearaudio · Post by **linearaudio** » Tue Nov 18, 2008 5:09 pm

Tacking the job initially, then building onto that as a base. Seems to have worked, but you end up with some bulky/ugly welds, hence the dressing back!

Post by **Alec** » Tue Nov 18, 2008 5:23 pm

Hello Alain,

firstly a good fit of all joints, i.e no gaps. Secondly is the right current and speed of welding. Comes down to experience. I'm assuming you want to use a MIG?

Alec

Post by **callyspoy** » Tue Nov 18, 2008 6:04 pm

that is a hoofin' bit of kit, loving it!

Post by **PSL184** » Tue Nov 18, 2008 6:20 pm

Yes, it looks lovely and swirly

linearaudio · Post by **linearaudio** » Tue Nov 18, 2008 6:27 pm

Used stick welder on it (shock horror) as the no gaps bit was a little difficult to enforce and I could envisage lots of stringy bits of wire inside the tubing with my SIP MIG! Mostly able to see down the inside as I worked and thus feel confident about the minimal gas flow disturbances! The spiral vortex will of course help to dodge any lumps (ha ha)

Post by **Alec** » Tue Nov 18, 2008 6:42 pm

Hello LA,

nothing wrong with a stick welder, but 1\16" is about the thinnest you'll weld easily. Gas is my favourite though, so flexible.

Alec

Post by **bmcecosse** » Tue Nov 18, 2008 7:43 pm

Looks great LA! Well done. Yes -I would gas weld steel tube too - but you have done very well indeed with stick!

Post by **wanderinstar** » Thu Nov 20, 2008 5:28 pm

Did you bend the pipes yourself or did you raid the exhast fitters skip and make it out of bits? If you bent it yourself, what did you use/

Sorry, just reread your first post.

Post by **alainmoran** » Thu Nov 20, 2008 7:22 pm

LINEARAUDIO wrote:I could envisage lots of stringy bits of wire inside the tubing with my SIP MIG!

Yeah, that's what I was worried about doing myself ... I guess I'll just have to be very careful with fitting the bits together.

linearaudio · Post by **linearaudio** » Thu Nov 20, 2008 8:52 pm

alainmoran wrote:
LINEARAUDIO wrote:I could envisage lots of stringy bits of wire inside the tubing with my SIP MIG!
Yeah, that's what I was worried about doing myself ... I guess I'll just have to be very careful with fitting the bits together.

Good luck holding all those carefully profiled cuts together while you juggle with the wire feed etc! I was using feet, knees, all sorts to wedge the bits while I was tacking. Still kept shifting. Patience is a grand thing, so is an angle grinder

Post by **bmcecosse** » Thu Nov 20, 2008 10:19 pm

There are some quite good magnetic clamps around !

Post by **alainmoran** » Fri Nov 21, 2008 12:42 am

I've never got on with the magnetic clamps ... so far my favourite tool has to be a set of g-cramps and/or a vice (or two)