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aja540i

M42 headers

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Have been meaning to make a replacement set of headers for the e36 for a while now, and finally got started on it, it will be good practice for when i do the same thing in the e21,

Laser cut flanges, U bends and donuts, all 44mm OD.

 

e36headers.jpg

Jig to hold flanges in factory locations

2016-07-31 09.52.56.jpg

homemade former to shape the ends of the primary tubes2016-07-31 11.03.04.jpg

primary tube pressed over former to shape end

2016-07-31 11.06.11.jpg

first 2 cylinders...

2016-07-31 13.16.05.jpg

all 4 started, test fitted at this stage, clears steering shaft (just)

2016-07-31 14.04.55.jpg

welding up each pipe individually before welding to flanges...

2016-08-06 21.25.14.jpg

will post more photos when i make some more progress.

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only suggestion would be to clean the tube up before welding. But it is an exhaust so rough enough. Fab work looks great. looking forward to seeing the merge's 

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I havent been at all fussy about how it looks as I'm going to wrap them anyway, I probably wont even bother cleaning the welds up. I will have to get some 51mm bends for the merges, I was going to keep it 44mm but 51 will fit better with th hole sizes in the second flange. Original tube size was 38ish.

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Are you aiming for equal lengths with your layout. The space for the rear cylinder makes this a challenge!

 

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Would be nice but not really possible with the steering shaft going right through the guts, just aiming for a bit more flow, and the old manifold was leaking anyway.

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You keen to come do some welding for me? I have a few things needing done on the projects :-)

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I should probably say no because I have so many things of my own I should be working on, but what do you need done?

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I need my air suspension welded up soon, but I have no gas for my bottle. I should probably just go rent a new bottle but like you, I have so many other things needed doing haha

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Started on the merge / secondary pipes, all 51 od, made another former to shape the ends

2016-08-13 11.27.05.jpg

2016-08-13 11.27.28.jpg2016-08-13 11.27.49.jpg2016-08-13 12.02.49.jpg

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Bugger, all welded up, painted, put in the oven to cure, then realised I forgot to weld the studs into the second flange!

2016-08-13 19.34.53.jpg

2016-08-13 19.42.33.jpg

so tomorrows job is weld the studs in, wrap them, and install.

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2016-08-14 12.44.52.jpg

Wrapped (mostly, ran out!) Painted again, baked and installed, car is quieter now due to 3 less leaks in the exhaust, but on hard left hand corners there is a very slight vibration in the steering, number 3 primary is just touching the steering shaft briefly as the motor moves. I will fix it properly one day, in the mean time I will only turn right ;)

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