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481 hits | 91.55 KB | Posted: 2/20/10
One piece of 1/2" x 2 1/2" flat stock long enough for two new header flanges.

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376 hits | 88.34 KB | Posted: 2/20/10
Fel-Pro 1415 exhaust gasket on top of the stock. I'll be cutting the ports to match the gasket but d...

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400 hits | 80.61 KB | Posted: 2/20/10
Gasket taped down with the center line of the ports aligned with the center line of the flat stock. ...

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407 hits | 92.5 KB | Posted: 2/20/10
Port outlines squared and scribed.

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397 hits | 79.91 KB | Posted: 2/20/10
Taped the gasket back down to the port outlines and punched the corners. That's a piece of 1/2" tube...

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344 hits | 104.25 KB | Posted: 2/20/10
I drilled a 1/8" pilot hole first with a step bit. Then finished it with a 1/8" twist bit. Next I ra...

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392 hits | 88.63 KB | Posted: 2/20/10
After all the holes were drilled I scored the lines with a cut-off wheel on my angle grinder. Then I...

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384 hits | 92.2 KB | Posted: 2/20/10
Once all the holes were roughed out I ground the sides smooth, straight, and square with a tungsten ...

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440 hits | 91.11 KB | Posted: 2/20/10
Gasket on top, finished ports in the middle. The cardboard on the bottom has the port layout from my...

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456 hits | 90.3 KB | Posted: 2/20/10
I used the cardboard to mark and drill the outermost bolt holes. Then I made relief cuts along the b...

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394 hits | 92.64 KB | Posted: 2/20/10
After I had clearance for the bolts and boots and got the plate sitting flush with the head, I neede...

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572 hits | 87.62 KB | Posted: 2/20/10
Finished flange with all the bolt holes drilled, spark plug boots and header bolts cleared, and port...

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490 hits | 84.1 KB | Posted: 3/14/10
Cutting the old header flanges off the headers. The weld penetration wasn't consistent so the surfac...

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554 hits | 86.59 KB | Posted: 3/14/10
Here the flanges have been cut off and a couple have been squared to match the flanges. I welded fou...

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476 hits | 91.62 KB | Posted: 3/14/10
All the tubes have been squared and hammered back into plane and alignment. It matches the flange si...

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478 hits | 67.83 KB | Posted: 3/14/10
The tubes tacked to the flange.

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439 hits | 68.15 KB | Posted: 3/14/10
I drilled and tapped a 1"x3"x24" piece of cold rolled steel to bolt the flange to while welding. It ...

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494 hits | 67.93 KB | Posted: 3/14/10
Both headers welded to their flanges and the ports ground smooth. I still need to grind the flanges ...