aja540i 1906 Report post Posted August 6, 2016 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. Jig to hold flanges in factory locations homemade former to shape the ends of the primary tubes primary tube pressed over former to shape end first 2 cylinders... all 4 started, test fitted at this stage, clears steering shaft (just) welding up each pipe individually before welding to flanges... will post more photos when i make some more progress. 6 Quote Share this post Link to post Share on other sites
thorburn 121 Report post Posted August 6, 2016 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 Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 6, 2016 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. Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted August 7, 2016 Are you aiming for equal lengths with your layout. The space for the rear cylinder makes this a challenge! Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 7, 2016 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. Quote Share this post Link to post Share on other sites
francoisv 466 Report post Posted August 9, 2016 You keen to come do some welding for me? I have a few things needing done on the projects :-) Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 10, 2016 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? 1 Quote Share this post Link to post Share on other sites
francoisv 466 Report post Posted August 10, 2016 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 Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 13, 2016 Started on the merge / secondary pipes, all 51 od, made another former to shape the ends 1 Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 13, 2016 On the home straight... Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 13, 2016 Bugger, all welded up, painted, put in the oven to cure, then realised I forgot to weld the studs into the second flange! so tomorrows job is weld the studs in, wrap them, and install. 1 Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted August 15, 2016 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 4 Quote Share this post Link to post Share on other sites
noera001 0 Report post Posted June 24, 2020 On 8/6/2016 at 5:21 PM, aja540i said: 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. Jig to hold flanges in factory locations homemade former to shape the ends of the primary tubes primary tube pressed over former to shape end first 2 cylinders... all 4 started, test fitted at this stage, clears steering shaft (just) welding up each pipe individually before welding to flanges... will post more photos when i make some more progress. Hi, I am wondering if you still have this header? Is it for sale or can you fabricate one for me? Quote Share this post Link to post Share on other sites
aja540i 1906 Report post Posted June 24, 2020 Sold them with the car, I have a standard factory set of headers if you are interested. Quote Share this post Link to post Share on other sites
