Help With Fabricating A Header (exhaust)

neXGen · September 3, 2006

Hey there guys..

Do any of you ll know a very good place where i could fabricate an exhaust manifold/header to be installed onto my car? Suresh says that he does not do headers as it is complex and most of his workers have left and as for Sasha, his work is based on turbo based applications and not normal aspirated engines..

Could ya guys recommend me a very good worksman/place where I could get it done at a very good price without losing out on the quality of worksmanship? Please let me know..

Thanx!

Zz

neXGen · September 3, 2006

Come on ppl.. aint there no one who has got any ideas/ppl??!!

Zz

Pericles · September 3, 2006

Sunday is not a good day to ask these things.

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Edited September 3, 2006 by MADZ

neXGen · September 3, 2006

K dude.. just let me know if there are any issues.. I seriously need to get this done asap.. thats the prob.. modifying a car which belongs to your dad is a tricky thing.. thats the scene :-)

Zz

Elvis_Pil · September 3, 2006

hmm what car was it again? and to what level of detail due you have the specs on the final product you hope to fabricate?

I'm just picturing the look on my pa's face if he saw a done header in his car! j/k lol

neXGen · September 3, 2006

Pilawoos said:

hmm what car was it again? and to what level of detail due you have the specs on the final product you hope to fabricate?

I'm just picturing the look on my pa's face if he saw a done header in his car! j/k lol

The Car is basically a Toyota Sprinter AE110 Auto Tranny.... the designs and everything are done by my buddy porkster.. just need someone to work at it ;-) .. it is not so complicated as the turbo designs but is quite complex in a way..

I doubt whether ma dad would take a real deep look inside the bonnet to notice... hehe.. even if he does.. its too late to do ANTHING!! :-) heehee...

Zz

gunat · September 6, 2006

ideally, you need someone who can do mandrel bends for your header (keeps the equal length as you bend the pipes)- and as far as i know, there isn't anyone who can explicitly do this with quality in mind.

http://www.se-r.net/header_exhaust/mandrel_crush_bends.htm

I'd recommend sticking to your stock Header and get a really good SS exhaust system- i think most of the SL car specialists would say the same, since the techonology to do headers in SL is almost non-existent.

Good luck

neXGen · September 6, 2006

gunat said:

ideally, you need someone who can do mandrel bends for your header (keeps the equal length as you bend the pipes)- and as far as i know, there isn't anyone who can explicitly do this with quality in mind.

http://www.se-r.net/header_exhaust/mandrel_crush_bends.htm

I'd recommend sticking to your stock Header and get a really good SS exhaust system- i think most of the SL car specialists would say the same, since the techonology to do headers in SL is almost non-existent.

Good luck

There were recommendations in old threads relating to certain people but unfortunately they do not do it no more as it is as you say kinda complex and require special equipment.. so am stuck searching for a suitable person but it is practically impossible over here in SL to do find someone of such expertise..

An alternative method which was told by a pal o mine is to get down the specific header for the model of my car.. the only problem being that the price is basically double the cost.. getting the exhaust done (minus the header) would be simple as Suresh told he could do it.. but it is the header which got me going a bit..

If things dont go well.. i suppose i will have to stick with your suggestion bro.. thanks for ya suggestion bro!! :-)

Zz

Elvis_Pil · September 6, 2006

sorry for the late reply- I've seen some header work done here and there.. but really its not worth it.. the bends are far to sharp on the inside which will restrict air flow (compared to say the DC sports one which I used at one time)- infact some of the these fabricated headers might slow you down! Also getting down one may not be worth it as the level of mods you can do on that particular engine is limited. If you like to try something out- I'd say go for a small port job on the inlets and outlet of the stock header after porting the engine as well.. -it may help.

neXGen · September 7, 2006

Pilawoos said:

sorry for the late reply- I've seen some header work done here and there.. but really its not worth it.. the bends are far to sharp on the inside which will restrict air flow (compared to say the DC sports one which I used at one time)- infact some of the these fabricated headers might slow you down! Also getting down one may not be worth it as the level of mods you can do on that particular engine is limited. If you like to try something out- I'd say go for a small port job on the inlets and outlet of the stock header after porting the engine as well.. -it may help.

I d agree.. thats why the search for such a individual is so hard.. from what i have read and learnt so far.. getting the header done would proove to be an increase in bhp by upto 10 bhp at times more.. The modifications which I have in mind basically should not in any manner increase the km/l ratio and keep fuel efficiency at its best while getting more bhp.. porting would most probably decrease the fuel efficiency nah?

wells, seems like i am stuck in a really complex situation lolz.. if things down go right I have only got 1 option and that is to get down the header or get a good quality heatwrap foil and cover the header.. there s very good proof that the more hotter the exhaust gas is, the more quicker it is to be expelled via the catalytic convertor n the rest... might result in +5 bhp hopefully... depends though..

do let me know bro if any good person to do the header pops into ya mind..

by the way, what would be the approximate costs of getting the engine ported eh?

thankz,

Zz

Elvis_Pil · September 7, 2006

Dude your economy will not 'scientifically' reduce due to porting.. but it will reduce as you will tend to step on the gas more lol Well you can try El*ard* they have the machinery to do it for sure. they once turned out a twin loop exhaust for me quite well.. only thing was I screwed up the perforaton ratio.

Dont worry too much about the header just get a proper exhaust done together with CAI- you'll have decent gains with out the loss of economy..

neXGen · September 7, 2006

Pilawoos said:

Dude your economy will not 'scientifically' reduce due to porting.. but it will reduce as you will tend to step on the gas more lol Well you can try El*ard* they have the machinery to do it for sure. they once turned out a twin loop exhaust for me quite well.. only thing was I screwed up the perforaton ratio.

Dont worry too much about the header just get a proper exhaust done together with CAI- you'll have decent gains with out the loss of economy..

lolz.. yeah the urge to go quicker will probably get my tank empty in no time.. I am not sure about elcardo cuz from what i heard mostly.. there work is not upto standards most of the time.. and especially in this case.. if things dont go right.. i might endup paying for the header which makes my engine drinks more gas n who knowz maybe even worse...

Wel... I have practically come to a decision of getting down the header which will be heat wrapped but as they say patience builds mountains.. so kinda looking around on top o the mountains hehe... CAI already done.. header and exhaust are the two on my list right now...

For now, porting and boring are just way ahead in my list :-) after all its ma dadz car and it outta run like a normal car .. @least for now that is... hehe...

btw, whats your car pila? you in wella?

Zz

porkster · September 7, 2006

neXGen said:

lolz.. yeah the urge to go quicker will probably get my tank empty in no time.. I am not sure about elcardo cuz from what i heard mostly.. there work is not upto standards most of the time.. and especially in this case.. if things dont go right.. i might endup paying for the header which makes my engine drinks more gas n who knowz maybe even worse...

Wel... I have practically come to a decision of getting down the header which will be heat wrapped but as they say patience builds mountains.. so kinda looking around on top o the mountains hehe... CAI already done.. header and exhaust are the two on my list right now...

For now, porting and boring are just way ahead in my list :-) after all its ma dadz car and it outta run like a normal car .. @least for now that is... hehe...

btw, whats your car pila? you in wella?

Zz

Ado ZZ,

Remember a car's exhaust systems starts where the gas comes out as in the exhaust ports, which is what the stock restrictive manifold bundled with a more restrictive CAT is attached to. So before doing post manifold mods best we put in that new header first. No your consumption will not be compromised but as said in earlier threads just cos you can go faster don't be a lead foot

It is unfortunate we cannot find a decent welder here with a mandrel machine so best we get it from USA. After doing your exhaust, heat wrap, custom 2" ss piping to the muffler, performance muffler (Monza will do in this case) we can look to adding an HKS AFR and slightly richening your air fuel mixture to handle the increase of air from the CAI. Lastly we can do the headwork.

Cheers, Porky

neXGen · September 7, 2006

porkster said:

Ado ZZ,

Remember a car's exhaust systems starts where the gas comes out as in the exhaust ports, which is what the stock restrictive manifold bundled with a more restrictive CAT is attached to. So before doing post manifold mods best we put in that new header first. No your consumption will not be compromised but as said in earlier threads just cos you can go faster don't be a lead foot

It is unfortunate we cannot find a decent welder here with a mandrel machine so best we get it from USA. After doing your exhaust, heat wrap, custom 2" ss piping to the muffler, performance muffler (Monza will do in this case) we can look to adding an HKS AFR and slightly richening your air fuel mixture to handle the increase of air from the CAI. Lastly we can do the headwork.

Cheers, Porky

Yo PorkY! lolz...

Not that I am gonna do any porting or anything related hehe.. just the need to know what it exactly is.. kinda complex and complicated it seems but interesting.. dont worry about the speed dude.. i know ma limits hehe... your step by step procedure o implementing the mods is somewhat like a good learning process where you learn the cars limits and somehow stick to it.. though the mods are really fancy and makes the car goes zoom.. lolz..

Yup.. am sticking to your listing order though the basic idea is to retain the "decent" car look with some fancy acceleration and speed backing it up ;-) Monza.. hmm.. i gotta have a look at it.. as for the rest of the mods.. hyak hyak.. pray to god that some decent soul wil fund me lmao.. well.. with time comes rewards.. so we ll see :-)

Zz