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TheV8Kid
TheV8Kid HalfDork
11/28/17 7:57 a.m.
maschinenbau said:

Would love to see photos of how you weld the collectors...mine always look terrible when I'm done. 

There are a few pictures of that process, two days from now.

TheV8Kid
TheV8Kid HalfDork
11/29/17 5:23 a.m.

Day 47 - December 31, 2016

Welded left tubes to flange. Cameron worked on firewall pattern.

TheV8Kid
TheV8Kid HalfDork
11/30/17 5:48 a.m.

Day 48 - January 1, 2017

Made first part of the firewall. Welded collector.

maschinenbau
maschinenbau Dork
11/30/17 9:58 a.m.

That is a fine looking header. Well done! So the "spike" in the center of the collector...is that basically 4 triangle extensions, one from each runner tube, welded from the inside and ground down? Or the spike a separate piece altogether? Then you slip the collector over the outside and weld from outside?

TheV8Kid
TheV8Kid HalfDork
11/30/17 10:16 a.m.

In reply to maschinenbau :

The spike is a separate piece altogether. It is welded to the four tubes, and blended with a belt sander. We have a ton of headers, so usually we use a piece cut off another header to make the outside portion of the collector. Then more blending with the belt sander. Sorry I don't have more pictures. It's kind of hard to go back in time to get more. 

mazdeuce - Seth
mazdeuce - Seth MegaDork
11/30/17 10:31 a.m.

I'm just curious as to the process. So you gather the four tubes, weld the pointy bit and....are there some other fillers on the outside of where the tubes meet? and once you get all of that done you can slip the collector on and do the rest of the welding from the outside? I guess I never thought about how it all works. 

TheV8Kid
TheV8Kid HalfDork
11/30/17 3:54 p.m.

In reply to mazdeuce - Seth :

Yes. Here are some better picures of the pointy bit. From the Datsun. 

Mr. Lee
Mr. Lee UberDork
11/30/17 4:42 p.m.

Is there an optimum lenght for the spikey bit?

wheels777
wheels777 SuperDork
12/1/17 4:11 a.m.

In reply to Mr. Lee :

Slightly shorter than the length as the 4-1 transition for a smaller collector, same length for a larger collector. 

wheels777
wheels777 SuperDork
12/1/17 4:42 a.m.

In reply to mazdeuce - Seth :

We fab or install 5 different types of collectors. 2 we make in house, 1 is mass produced and 2 are mass produced but modified.  Each is selected for their own reasons. Choices include NA, N2O power level, firing order, rotational timing, 180 degree etc.   The fabricated collectors are similar to merge collectors. We add internal features not marketed. 180 headers are typically 20% smaller at the opening. NA headers for all out efforts are internally blended and transitioned and made to a specific length. BBC Headers don't get some features because there are many 7-4 swap cams out there. 7-4 swaps help the tune on cylinder number 2.

Long story short, the header above is BBC - N2O - no feature - stamped collector - not equal length. It is the most simple basic collector we install - nothing special - no specific sizing - just slip on and weld. 

TheV8Kid
TheV8Kid HalfDork
12/1/17 5:28 a.m.

Day 49 - January 2, 2017

Finished second collector. Began firewall work.

mazdeuce - Seth
mazdeuce - Seth MegaDork
12/1/17 6:54 a.m.

Other than having a house full of Nelsons to sit down to dinner with, where does one go to learn header theory? 

Patrick
Patrick MegaDork
12/1/17 7:41 a.m.
mazdeuce - Seth said:

Other than having a house full of Nelsons to sit down to dinner with, where does one go to learn header theory? 

To be fair, when breaking bread with the Nelsons, header theory has never come up.  It’s always been about family.  

Dusterbd13
Dusterbd13 MegaDork
12/1/17 7:44 a.m.
Patrick said:
mazdeuce - Seth said:

Other than having a house full of Nelsons to sit down to dinner with, where does one go to learn header theory? 

To be fair, when breaking bread with the Nelsons, header theory has never come up.  It’s always been about family.  

And thats why I love this place. Family first.

 

But I'll second Seth: where are some good reads on this stuff? Its relevant to my interest. 

wheels777
wheels777 SuperDork
12/1/17 7:58 a.m.
mazdeuce - Seth said:

Other than having a house full of Nelsons to sit down to dinner with, where does one go to learn header theory? 

Studied every document I could get on headers, tuning, pulsation etc while getting an Engineering degree from PSU - it was incredible to connect racer theory and empirical data to proven science.  Worked with a National level Competition Eliminator Team while in college.  Did hundreds and hundreds and hundreds of tests at dragstrips.  Provided parts and info to other racers who proved things out on dyno tests.  Studied flow generated vibration and pulsation cancellation technology at Research Institute.  Directly involved in emissions technology development thru the mid-90's.  Consult with/for Engine Specialists and Manufacturers for odd fire reciprocating engine exhaust systems.  A lot of neat experiences over 38 years of being involved with racing.  Fun factiod - my day job is to help manage a fleet of 139 engines that make 1.2 million HP - 2 of those engines are slow speed recips that make 1.5 million #*ft of torque...each.

Pete Gossett
Pete Gossett MegaDork
12/1/17 8:38 a.m.

In reply to wheels777 :

Did you build headers for them too???

wheels777
wheels777 SuperDork
12/1/17 8:43 a.m.
Pete Gossett said:

In reply to wheels777 :

Did you build headers for them too???

Okay back to the Nova build...

TheV8Kid
TheV8Kid HalfDork
12/2/17 6:52 a.m.

Day 50 - January 3, 2017 

More scrap metal destined for glory. Left side firewall panel started.

TheV8Kid
TheV8Kid HalfDork
12/3/17 7:41 a.m.

Day 51 - January 4, 2017

Left firewall panel installed.

TheV8Kid
TheV8Kid HalfDork
12/4/17 5:29 a.m.

Day 52 - January 7, 2017

Began making transmission cross member. A 4l80e and th400 will bolt up directly. The captive nuts are there so that a simple bracket could be made for th350, powerglide, or whatever else.

Andy Neuman
Andy Neuman Dork
12/4/17 12:41 p.m.

Posting every day makes it seem like it comes together so fast when we aren't waiting a week for an update like the timeline shows. 

mazdeuce - Seth
mazdeuce - Seth MegaDork
12/4/17 12:49 p.m.

Do you guys do anything to the inside of pieces like that to prevent rust? I know you're not looking at 100K miles of daily driving in salt country, but I'm always curious as to what's going on inside. 

maschinenbau
maschinenbau Dork
12/4/17 1:55 p.m.

If you completely box it in, corrosion will have a hard time without much water or oxygen. Or at least that's what I hope!

wheels777
wheels777 SuperDork
12/4/17 2:04 p.m.
maschinenbau said:

If you completely box it in, corrosion will have a hard time without much water or oxygen. Or at least that's what I hope!

Correct.  And, it's .097" thick.

java230
java230 SuperDork
12/4/17 2:13 p.m.

Thanks for putting in all the updates, fun to see it come together so fast, when in reality it takes soooo long.

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