Change font size


Post a new topicPost a reply Page 2 of 2   [ 27 posts ]
Go to page Previous  1, 2
Author Message
 Post subject: Re: Stainless Steel Headers
PostPosted: Mon May 29, 2017 8:30 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
OK - it's been far too long for these to get done. I've stopped all my other projects to get the 4 remaining headers done in the next few weeks. So let's get some progress photo's up.

Here's how I started. Put the mock-up header in the jig and add in the hard brackets to position all the tubes.

Image

Muffler clamps of the correct dimension work wonders.

Image

Not the best photo - but you can see the various angles. Some have been further tweaked in the first production unit to make everything perfect.

Then I cut up all the transitions and polished the tubes again with a fancy 3M belt on the giant grinder. Works very well.

Image

Then it was time to tack them all up. Nice tight gaps.

Image

Easier when you're not making it all for the first time.

First branches going together. I'm not able to put much time in the garage right now - so updates will be slow. I can't wait to put this project to bed.

Image

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Tue May 30, 2017 10:16 pm 
First volvo in outer space
User avatar

Joined: Fri Dec 14, 2007 1:46 pm
Posts: 1648
Location: East L.A.
Shiny!! =D>

_________________
Jim

66 122S (Garage Queen)
89 244 (Hers)
90 745Ti (Mine)
89 744 (SOLD/Bought back for other daughter)
78 242GT (Project... LOL)
91 244 (Don't Ask!!)


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Sat Jun 10, 2017 4:33 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
Ok - so we're chugging like a train to get these done. The eagle-eye'ed among you will have noted that the 45 degree bends are clearly not coming in at the same angle. That meant I had to adjust the jig, fix, fiddle and basically kill a day. I wish my mock up header was a little more accurate. I can't build things in a production mode if everything is a little off here and there.

So with that done (no pics - I'm getting lazy) - I cranked out the 1-4 branches.

Image

That was the rest of the week. Not too bad once I had a process all down.

Today saw the 2-3 branch get sorted out. Same deal - scrap the jig, rebuild, then work out all the angles, test fit, modify jig until it was perfect and we arrive at this.

Everything nice and straight.

Image

Just have to break it all apart for welding now.

Image

Image

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Sun Jun 11, 2017 4:59 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
Got the rest of the headers tacked up today. Once you get the jig working and dimensions sorted out then it goes a little easier. It's still takes quite a long time to get the fits nice and I'm still worried about how they will all turn out, but it's on to the next phase. Welding.

Image

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Fri Jun 23, 2017 10:26 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
Almost time to wrap this thread up...here's the mock up header all cleaned up, welded and ready to ship.

Image

img]https://c1.staticflickr.com/5/4261/34686955283_a796b4d7e2_b.jpg[/img]

Carbs and heat shield fit perfectly.

Image

Unfortunately it takes me a full 8 hour day to weld these up. I'm working as fast as I know how to go...it's just taking that much time. So there are now 3, and will be 5 by next week.

Image

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Mon Jun 26, 2017 7:10 am 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Dec 21, 2005 8:40 pm
Posts: 3492
Location: Calgary, Ab
That's a shiny pile of quality, right there. Great work Craig!


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Wed Jun 28, 2017 10:48 am 
First volvo in outer space
User avatar

Joined: Fri Dec 14, 2007 1:46 pm
Posts: 1648
Location: East L.A.
Ugly Duck wrote:
That's a shiny pile of quality, right there. Great work Craig!


What Matt said, those look stunning, probably flow pretty good too...

_________________
Jim

66 122S (Garage Queen)
89 244 (Hers)
90 745Ti (Mine)
89 744 (SOLD/Bought back for other daughter)
78 242GT (Project... LOL)
91 244 (Don't Ask!!)


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Sun Aug 20, 2017 8:27 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
One last header needed to get built. The rest were done a few weeks ago and just need to have the flanges flattened before putting them up for sale. This header was the original conception for my planned special B20. The engine will have my rather unique B20 head with the welded up exhaust ports, 44/38 valves and the usual porting tricks. My previous calculations indicated that the port size was too large and the only solution was either to weld up the port or build a header with tongues that block off the bottom of the port (I've done one of these as well).

Here's the head.

Image

The special flange.

Image

Sized to fit the 1.5" tube when installed.

Image

Starter tubes taking shape. Just hammered them on 4 sides to make them square.

Image

Image

A little polish...you know this had to happen some time.

Image

A lot of polishing on the tubes.

Image

The 2-3 branch was designed to come straight out...the car will be fuel injected and won't need to clear the carbs...it will also improve the tuning a little.

Image

The merges are very hard to get nice welds on. Practice makes for pretty close to perfect.

Image

Flanges are also difficult. This one welded up very nicely.

Image

All done. Will make noise some day!

Image

Image

Done - that's it for now. I'll return with a turbo manifold build in a while.

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Wed Aug 23, 2017 9:42 pm 
Bone stock

Joined: Thu Aug 04, 2016 10:10 pm
Posts: 18
Location: Southern Alberta
Fantastic result, makes me wish I had an engine to put it on!


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Tue Aug 29, 2017 9:29 am 
First volvo in outer space
User avatar

Joined: Fri Dec 14, 2007 1:46 pm
Posts: 1648
Location: East L.A.
Works of art for sure. =D> You mention a header for the "special B20", any hints on a destination??

_________________
Jim

66 122S (Garage Queen)
89 244 (Hers)
90 745Ti (Mine)
89 744 (SOLD/Bought back for other daughter)
78 242GT (Project... LOL)
91 244 (Don't Ask!!)


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Tue Aug 29, 2017 5:53 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
User avatar

Joined: Wed Jun 14, 2006 4:19 pm
Posts: 3131
Location: Lethbridge, AB
woodenshoes wrote:
Works of art for sure. =D> You mention a header for the "special B20", any hints on a destination??


I've lusted after the local 1800ES for years...informing the owner that he's only taking care of my car until he want's to sell it to me. The B20 that was in my 122 with the 11:1 compression head and bigger cam and EFI conversion are going to eventually make it into an ES of some sort. I'm thinking that's the next project as 911's are just priced too hight for the junk that I've seen. I am making a car already that will scare the crap out of me...I may want a real GT for touring. I also think that restoring a car instead of re-engineering a car has a built in intelligence that heretofore I've missed, and now appreciate.

_________________
Coburn Performance - OCD comes naturally.


Top
 Profile  
 
 Post subject: Re: Stainless Steel Headers
PostPosted: Wed Aug 30, 2017 8:46 am 
First volvo in outer space
User avatar

Joined: Fri Dec 14, 2007 1:46 pm
Posts: 1648
Location: East L.A.
:lol: I seldom see another Volvo around town, but see John in his ES a couple of times a year? That will be a nice little motor in that car if/when it happens.

_________________
Jim

66 122S (Garage Queen)
89 244 (Hers)
90 745Ti (Mine)
89 744 (SOLD/Bought back for other daughter)
78 242GT (Project... LOL)
91 244 (Don't Ask!!)


Top
 Profile  
 
Display posts from previous:  Sort by  
Post a new topicPost a reply Page 2 of 2   [ 27 posts ]
Go to page Previous  1, 2


Who is online

Users browsing this forum: No registered users and 1 guest


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Jump to:  
cron


Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group
610nm Style by Daniel St. Jules of Gamexe.net