how much does it cost to make these headers?
 

Hi I just came upon this forum, and would like opinions on costs and complexity of turbo header fabrication. There is a header design for 3000gt's that only fits overpriced greddy turbos, and a smallish wastegate. How much time and how much would it cost to make a 1-off of the greddy header design, except with the standard TD05 exhaust flange and provisions for 40mm tial wastegates? I don't really care if the runners are not perfectly equal length, but approximate. Pictures:

http://www.dynamicracing.com/custome...&cat=19&page=1

Re:how much does it cost to make these headers?
 

I know a guy local who could do that job, for less than a grand, that does great work.. Only problem is that he needs to have the car in order for him to do it.. clearences/distances etc..

I would say the avg is going to be about 800-1000 bucks.

https://www.homemadeturbo.com/turbo/racezc/mana.jpg
here is a pic of a manifold he did for me, that cost around 600 bucks, with no flanges, included dp, and wastegate pipe..

Jeff

Re:how much does it cost to make these headers?
 

I'm down south in California. That's a great price for headers, and the weld quality looks top notch. ;)

Re:how much does it cost to make these headers?
 

i was looking to have a custom made manifold... because i couldnt find an HF anywhere.... i went to TIjuana... believe it or not... some dude at a muffler shop said he would bend the pipes and weld the ---- together for 40$ only you have to make the flanges and everything... thats pretty good... but im still having trouble cutting out the flanges

Re:how much does it cost to make these headers?
 

This is seriously ghetto, but if you have no access to a drill press, plasma cutter, etc it is possible to use a Jig Saw... lol
I've done this before, and worked on 1/4 mild. Used a hand drill to do pilot holes, Jig for most of the straight cuts, and dremel to clean it up.
On some of my 1/2 mild stuff, I just made nice templates out of some old plexiglass, and took it to a local welder to cut for me.
Cant wait to play with some Weld-Els to make custom Mani's! You ever use that stuff Jeff?

Re:how much does it cost to make these headers?
 

There's also another thing I'm looking into. This is a design that bolts straight up to the stock headers of a V6 engine. It's much easier to build compared to the headers I posted earlier and I would also like cost opinions (with ceramic coating) on it. Let's assume that a HKS GT 60mm wastegate and a huge single turbo is utilized. That means not melting down when supporting 800-1100hp worth of exhaust energy. It's also not a PITA to measure out (3000GT rear cylinder bank is a nightmare). Here's a pic to illustrate my ideas:

http://perso.wanadoo.fr/olivier.p24/...x/echap077.jpg
(Ford probe turbo kit)

Re:how much does it cost to make these headers?
 

hey leed were can you get weld els i want to start making manifolds soon and i think those will be much easier than ss tubing and cheaper.

Beau

Re:how much does it cost to make these headers?
 

put me down for a B16 manifold, if its within the next 1-3 months...

Re:how much does it cost to make these headers?
 

From what I under stand an industrial supply store should carry them. I'm sure there is one somewhere in Everett, Tacoma, or Seattle.

They are online here:
http://www.mcmaster.com/

Just do a search for "Unthreaded Steel Butt-Weld Pipe Fittings"
Just imagine all the cool ---- you could make with this stuff! A bit pricey for stainless, but still a fraction of the cost for a competed unit.
Lost of other cool ---- on this site too!
Having seen one of DropShops 'log' mani's, this is the stuff they used. Total cost for manifold is around $25-$50 depending on source for flange material.

Re:how much does it cost to make these headers?
 

great site leed with the ---- i just found on that page a street crossmember will be no problem.
thank you

Beau

Re:how much does it cost to make these headers?
 

Abaz: Can I email you a few compressed diagrams of my single turbo design when I get a scanner? I'm very interested in your local resource in the near future. ;)

Re:how much does it cost to make these headers?
 

I think the only way the guy I know will do something, is if it see's the item in front of him, so he really knows what he is working with.

Jeff

Re:how much does it cost to make these headers?
 

I can send diagrams,stock headers, and the stock downpipe if he's talking about items. I'm going to start taking measurements as soon as I obtain turbocharger dimensions.

Re:how much does it cost to make these headers?
 

not hard to make at all if you have a drill press, 1/4 to 3/8 flat stock, ubends and jbends.. "jcwhitney has them" ,a hack saw, and a mig/tig welder.

trace the exhaust gasket onto the flat stock, drill with a bimetal holesaw on the drill press "lots of oil".
Cut your u/j bends to length/shape, tack it all up, buy a collector online at summit racing. weld it all together, use any flange you like..!

http://www.freephoto-i.net/browse.php?album_id=3104

here is a small photo album of the project check it out....
Wildman ;D

Re:how much does it cost to make these headers?
 

How abou if I were to go around the my area's muffler shops, and ask? It's most likely a more economical choice than going to a full fledged machine shop right?

Re:how much does it cost to make these headers?
 

thought id touch this. since there was someone asking about jc whitney ubends in turbo header application.. ;)

Re:how much does it cost to make these headers?
 

wait a minute.
our exhaust holes are not round so u couldnt use a bi metal hole saw.

Re:how much does it cost to make these headers?
 

you could use a smaller hole saw then use a die grinder to make it oval.

Beau

Re:how much does it cost to make these headers?
 

beau is correct thats exactly whay i did mine are oval as well. your welding right there anyway so you can actually go beyond the tube into the weld to get an oval to round transition.