How To Make Custom Headers - Relative Collectors Setup's

As an aside, 1,400 hp means each primary tube in the header needs to support 1400 / 8 hp = 175 hp. Doing the same calculation 175 x 2.2 / 115 = 3.3 square inches. The area of a 2-inch tube is 3.1 square inches, so the headers might be the limiting factor in ultimate horsepower in Unfair.

Working the calculation backwards, we see that the 2-inch headers will theoretically limit the engine to 1,300 hp. Stay tuned. We'll see how that engine turns out on the dyno pretty soon!-John Parsons.

With perfect tube fitting and back-purging comes these gorgeous rose and golden colored welds, with minimal heat affected zones.
With perfect tube fitting and back-purging comes these gorgeous rose and golden colored we
Once all the tubes are fully welded, it's time to secure them to head flanges. All the tubes are positioned and tack-welded to the flange...
Once all the tubes are fully welded, it's time to secure them to head flanges. All the tub
...and tacked together inside the collector simulator.

Here's a better look at the tubes tacked to the flange after the nearly done header has been removed from the car.
Here's a better look at the tubes tacked to the flange after the nearly done header has be
If the tubes are placed squarely in the header flange, they should all be nearly flush with the inside edge of the flange.
If the tubes are placed squarely in the header flange, they should all be nearly flush wit
This makes it easy to fully weld them to the inside edge.

This shot shows the relative sizes of 4-, 3.5-, and 3-inch collectors, along with Cone's cool inner tube merge setup.
This shot shows the relative sizes of 4-, 3.5-, and 3-inch collectors, along with Cone's c
The first step is cut all the tubes square and even with each other. Our Femi bandsaw makes short work of that task. Note how he left the collector simulator on to keep the tubes properly aligned until they are welded together.
The first step is cut all the tubes square and even with each other. Our Femi bandsaw make
After cutting and some cleanup with a file, the collector is ready to be welded together.

First, the inner deflector is welded to the ends of the tubes.
And finally the outer collector is welded to the tubes.
Here's a look inside the collector after all the welding is complete.

SOURCES
Prodigy Customs Apopka FL 407-832-1752 www.prodigycustoms.com	Cone Engineering 800-795-5535 www.coneeng.com
II Much Fabrication Germantown MD www.iimuchfabrication.com