Building Turbo Headers

Here is what the car was before i got a brilliant idea


here was the brilliant idea


had to get the exhaust housing coated, didn't want it to rust


then i had to polish the big idea (special thanks to andrewF for the polishing skills)


then it was finished


Nitrous setup would have been way cheaper to keep


so back it into the new garage and take it apart


stick the turbo in and see where it will fit


we played with a lot of options














We planned to put the turbo on the passenger side somewhere,
then we started on the header building, figuring the headers
will be harder to make and we can move the turbo around to mate
to the headers would be easier.

I ordered a chris alstons make your own header kit out of mild steel.
I knew i wanted to use stainless, but i didn't want to be messing up on
expensive stainless tubing so i would make it out of MS and then i can
tweak it and play around to get the design down before messing with the stainless parts



started off pretty easy










making the last tube fit

everything is just tac welded to make it easier to bend or separate

another angle

here is both headers



so after doing that i started with the stainless
you can see the makeshift band saw we used to cut the tubing it actually worked out so well!!


always be careful when working with power tools


table where i made the headers


deburring all the edges



inside and outside


checking clearances since it will be tig welded no gaps


tack tigging the first piece


getting the second pipe ready


fusion welding on the collectors


preparing for the collector to go on, the hardest part of the header construction









let the welding begin



finished product