Welcoming a new addition to the fleet

have you done a gas analysis of the effect this will have?

Freelaner said:

have you done a gas analysis of the effect this will have?

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be reeeeeet the header on one side was longer anyway so this brings them up to the same size

Dr_evil said:

be reeeeeet the header on one side was longer anyway so this brings them up to the same size

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well same length as each other will help

indeed plus it lets me try out some stainless stick welding again

not done it for a while

Good news I have a new wheel bearing! And enough stainless and hopefully enough welding rods to complete the exhaust set up tomorrow

If so there'll be a video of a very very noisy V8

Dr_evil said:

Good news I have a new wheel bearing! And enough stainless and hopefully enough welding rods to complete the exhaust set up tomorrow

If so there'll be a video of a very very noisy V8

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ok,thats great.but who's v8 will it be?.

pics of the headers after they are done, and before you install them. Would be nice

gemsdad said:

ok,thats great.but who's v8 will it be?.

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Feck off

Thor1950 said:

pics of the headers after they are done, and before you install them. Would be nice

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I'll take a pic if I clean them up if not I'll just install them then take a pic.......its not the neatest job as I've had to cut and stitch random bits of pipe together in order to make them fit within the chassis rails.
Rather hard to get a grinder into the headers to clean them up with a flap disc, but stainless stick welding is nice and easy

Made more progress on the headers today........proper bastard to weld!

Gotta be at 50A to burn the 2mm rods properly meaning I can only stitch it together in 1" ish stages. As well as that because its a weird bend I've got to cut, shape and patch bits of stainless together which is a pain in the arse.


Anyway a few pics, its about 75% complete now tomorrow I'm going to finish cutting and stitching then flap disc the entire thing or at least as much as I can get to just to tidy up the manifold.

One issue due to the series ones chassis and being so bloody narrow is that because I've had to modify the angle of the pipe to fit on the front the bottom bolt on exhaust port one has to now become a stud.

Luckily I have some bolts I can cut up and use as studs











The rear of the passenger side is extended and the flexi removed











The front two are cut and welded on closer to horizontal and then merged together into one pipe










Heres the nearly finished piece made up of a stupid amount of little bastard bits of stainless creating what can only be described as one ugly ass passenger side header. Really could use some 16g rods instead of these 12s

YOU SAID IT WOULD BE REEEEET! PUT THE PIGEONS AWAY!

Awful lot of work for P38 manifolds... if you can call them that now!

Well its not the pigeon shat everywhere!

At least it didn't leave any flux in the welds just a few lines of inch long slugs stuck back to back

Be fine with a clean up anyway and I know but I cant fit anything else those are the best "headers" I can possibly fit due to the chassis and body

Only question I got is how much weld( goobers) is on the inside to to cause a flow issue

None, all plates are overlapped onto the previous or butt welded via a series of painstakingly applied tack welds and same for any pipes

I didn't blow through either because I could only weld an inch at a time on the larger sections

Turns out I'm 2mm short on the drivers side due to a little ridge thats on the engine mount.......now I could slice this ridge off but that would be silly so what I'm doing is simply drilling the holes on the manifold to a larger size. Tomorrow I'll be up early and off the engineers supply shop so I can pick up a 15mm and 17mm bit. This means I can simply slide the manifold over slightly without having to cut the chassis (this is after bashing the manifold with a hammer btw! just to decrease the clearance needed)

The same goes for the passenger side but it is now leak free

Dr_evil said:

Turns out I'm 2mm short on the drivers side due to a little ridge thats on the engine mount.......now I could slice this ridge off but that would be silly so what I'm doing is simply drilling the holes on the manifold to a larger size. Tomorrow I'll be up early and off the engineers supply shop so I can pick up a 15mm and 17mm bit. This means I can simply slide the manifold over slightly without having to cut the chassis (this is after bashing the manifold with a hammer btw! just to decrease the clearance needed)

The same goes for the passenger side but it is now leak free

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won't that restrict exhaust flow a wee bit

Thor1950 said:

won't that restrict exhaust flow a wee bit

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Near enough makes no difference tbh, the old P6 manifolds that came off were ridiculously strangling to the system so even if these are over 2mm it should still make a good difference.

Especially as the engines got an exhaust bore to match the top end now instead of running on 1.25" pipe its on the correct 2.5" downpipes or 2.25" cant remember which without measuring

Manifolds are on......bastard of a job to fit them! 90* bends ordered up too so I should be able to get the system finished this evening


More pressing matters to attend to before then like getting my series 3 fuel gauge working

Looks like the HG may be on the way out.......now this wouldn't surprise me given that I accidentally let it overheat last time I took it laning


Forgot to turn the electric fan back on (really should wire in a relay to a thermostat switch at some point or a permanent live on ignition) and it hit 115 out of the 120 on the gauge before I noticed and killed the engine to cool it for 10 mins!




I removed the spark plug in cylinder 4 and 6 to check plug colour and as I removed plug 4 some liquid squirted out of the plug hole........tasted the plug and it was antifreeze That may also explain its recent reluctance to start

You've broken it already???????????