Headers No. 1

[Clayton105]

A while back, there was some discussion about the correct exit angle of headers out of the head for a Nord engine. It got me thinking... Danger Will Robinson!

What is the correct exit angle? I have a couple of mates with race rally Alfas with pretty sh*t headers and considering there is a lack of good off the shelf Alfa systems here in Aus, I thought I would whip up a couple for them.

For example, this picture is looking down the exhaust of a set of "custom made, race headers". The scribe points to the wrong orientation of the pipe at a point critical to maintaining high velocity and intertia.

Crap, hey?



So:

1. Get a head and measure it up.
2. Draw it up on Acad.
3. Design a flange.
4. Get it laser cut.



5. Make a really high tech jig an get to work with your burr to get the pipe to exit at the right angle.





6. Make up some stubs. cutting them to the right angle.



Continued next post...

[Clayton105]

7. Weld together and check that they are pointed in the right direction.



Just to prove it... (the lump at the lower right is to give clearance for the upper nuts)



And before anyone makes any comments about the welding: borrowed welder with one manky tip that was undersized and well past it's use by date. And of course I would have used a TIG had I just had one floating around (like everyone else who can actually competently use one would...).