Fenderwell exit headers in progress

[Poison Heart]

I always liked the look of gassers and fenderwell exit headers are the best way for me to get away from the steering, starter and clutch linkage. And since I'm going over the frame instead of under there won't be any ground clearance issues.

I started off using the Hedman 4 tubes I bought. I forget what they're from. I bought them used, I think the guy had an early 80s Firbird??? So far I chopped the main pipes as close to the flange as I could. I cut a few pieces and kind of figured out where each pipe is going to go. I'll post pictures. I need to cut some of the inner fender out so I'll make more progress next time I go out there. Hopefully Friday.

The thing I'm most concerned about right now is the 2 middle pipes. Seems like a tough weld between the 2. Will I have to get this part tig welded? Is it possible with a mig?

[starchief1959]

Hope you get this figured out. Curious to see how you get them routed.

[Scruffy]

Ya got some work ahead of ya, not sure on the welding thing, would have to see it, anyway, good luck getting em done.

[Poison Heart]

I'll post some pics next time I go out there. The only real problem with the routing is the back tube has to come forward a little to clear the steering column. The others should be easy to get over the frame. It'll be tight but I think I can do it. I've never made headers before but I guess this is a good time to start.

[Scruffy]

U may have to cut off the two center tubes, grind them out of the flange an weld in new tubes from the engine side of the flange,

[Sirrotica]

I've made headers before and sometimes oxy acetylene welding is the best in confined quarters such as the area your working on, and when you go to weld the collectors to the pipes also. Tig welding will work here also, but I didn't have access to a tig welder at the time I did mine. There are oxy acetylene welding tips that are straight for welding inside of pipes etc. A mig will work for the majority of the welding, but not all of it. Good luck on tackling a rather difficult task.

[Poison Heart]

The guy I used to work for is a certified tig welder. I was thinking about getting him to finish weld the tough parts. We'll see how it goes.

[Sirrotica]

If you can tack weld it together and get him to finish it off for you that should work fine.

[Poison Heart]

That's what I'm gunna do. What does a pneumatic mandrel bender cost? One that can do small primary pipes like these?

[Sirrotica]

Buy some header bends I know Hooker used to sell them, they are pipes that they couldn't use and instead of throwing them out they sell the mistakes pretty cheap if I remember correctly. Anything that bends mandrel bends is gonna be expensive. I was fortunate and I had a friend that worked in a muffler warehouse and he let me use their bender to make my headers. Now ya see why custom made headers are quite expensive. Alotta time is consumed building them.

[The Chief]

buddy of mine build systems for a living, specialist systems for F1 cars etc all inknel and always gaswelded inside and out

[Sirrotica]

I found a company that makes manual, and manual over hydralic tube benders. They aren't real cheap but probably as low priced as you can find. Notice they don't reccomend the 100 dollar jack benders that places like Harbor freight sell as they will just flatten tubing out and kink it. I know this to be true as I have one of these cheap ass pipe benders myself and it won't bend tubing.

Link: Williams Lowbuck Tools, Inc. Home Page

[Poison Heart]

Thanks for that link. $500 for the cheapest one isn't too bad. It does tubes up to 1.75" Which is big enough for my headers. But with that I could make my own headers for anything. I think I'm going to save up and buy one. That's a pretty handy tool.

[Sirrotica]

NP yes it's something you can use over and over probably a good investment in the long run. You surely won't get custom headers for what you'd pay for the bender and if you do 2 sets you'll be money ahead.

[Poison Heart]

That's what I figure. A couple sets and I'd have my moneys worth.

[Sirrotica]

Just to let ya know on your 62, GTO headers will fit so you won't need to build those ones. When we raced 61 Pontiacs on dirt tracks we found GTO headers fit.

[Poison Heart]

No shit? Hell yeah! Too bad I just chopped mine up for my 59. hahaha

[Sirrotica]

Do ya ever feel ya just don't live right?.... At least GTO headers are usually easy to find used.

[Poison Heart]

haha yeah, oh well. Maybe I'll get that tubing bender and make my own anyway.

[The Chief]

What year GTO? will they work on the catalina aswell?