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modok
Samba Member
Joined: October 30, 2009
Posts: 26787
Location: Colorado Springs
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 Posted: Sat Jan 12, 2019 2:41 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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I have a whole pile of 1 3/8 stainless J bends, I get them from summit or jegs.
What i still cannot find is aluminized 1 3/8, but that's ok maybe stainless is better for that part of the header.
A lot of VWs have a problem where they run too cool around 3200 rpm, and too hot around 4000 rpm, because of how the header tunes in and out. i was able to reverse that so now it runs about the same temp all through.
Also, far as "success", if you get the secondary and collector sizes just right or a little conservative side, should be able to engage the clutch at idle, THEN floor it, and should pull up smooth all the way to redline with no hickups.
So many engines CAN"T do that that guys think it's impossible.....but actually it IS possible, although not necessarily needed, it is possible and a lot being able to do that is in the header. |
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67rustavenger 
Samba Member
Joined: February 24, 2015
Posts: 9767
Location: Oregon
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| Posted: Sat Jan 12, 2019 2:53 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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Just a little problem on my side of the rockies.
I have a mig welder. Not tig. I also have no purge setup for clean welds on the I.D. of the stainless tubing. It's likely not real healty for a turbo to ingest chunks of "burnt sugar" from unpurged stainless welds.
| modok wrote: |
I have a whole pile of 1 3/8 stainless J bends, I get them from summit or jegs.
What i still cannot find is aluminized 1 3/8, but that's ok maybe stainless is better for that part of the header.
A lot of VWs have a problem where they run too cool around 3200 rpm, and too hot around 4000 rpm, because of how the header tunes in and out. i was able to reverse that so now it runs about the same temp all through.
Also, far as "success", if you get the secondary and collector sizes just right or a little conservative side, should be able to engage the clutch at idle, THEN floor it, and should pull up smooth all the way to redline with no hickups.
So many engines CAN"T do that that guys think it's impossible.....but actually it IS possible, although not necessarily needed, it is possible and a lot being able to do that is in the header. |
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo! |
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modok
Samba Member
Joined: October 30, 2009
Posts: 26787
Location: Colorado Springs
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| Posted: Sat Jan 12, 2019 8:55 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| buy/build an expander, flare the end of one tube, and do lap welds. |
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saw2
Samba Member
Joined: November 06, 2008
Posts: 321
Location: nw Oregon
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| Posted: Mon Jan 14, 2019 12:54 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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67rust, yes I have bought a couple exhaust bends over the counter at Columbia River Mandrel Bending. They are located in downtown St. Helens. I just gave them a call and they said stop by office and talk to them.
So not sure if they are really a retail play but it worked for me. |
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mark tucker
Samba Member
Joined: April 08, 2009
Posts: 23937
Location: SHALIMAR ,FLORIDA
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| Posted: Mon Jan 14, 2019 1:28 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| modok wrote: |
| buy/build an expander, flare the end of one tube, and do lap welds. |
many ss headers are done that way to save $$$ done with a mig .dosent look as good but works great. if your good with a mig you can make a very very nice ss weld.I first started migging ss about 30 years ago. anti reversion chambers can also be built into the tubes for long exhaust duration cams to help with pulling ex back in at lower rpm. |
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nogoodwithusernames
Samba Member
Joined: November 10, 2014
Posts: 599
Location: CA, USA
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| Posted: Mon Jan 14, 2019 9:20 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| DeathBySnuSnu wrote: |
I also built my own headers. I have an odd app and the desire to be different also. Mine wound up being a 4 into 2 split header. It seems to work, but I dont have anything to compare it to. I did get on a wheel dyno once and made good numbers. But since then I have changed a good bit of stuff with the tuning. I have become more concerned with making it fun to drive instead of peak hp on a dyno.
So with a 2387 and fk10.
1-5/8 out of head for the first few inches.
Then an anti reversion can.
Then 1-3/4 short tube (calculated length using online sources) of 34" long from valve.
Then a steep tri-y style (2 into 1) with a 2" collector.
Then a 2-1/2 anti reversion can with a 2" outlet.
It made good numbers.....but nothing to compare it to......would it make better with a store bought header? I will never know (wont fit) and I am happy with the results.
Bottom line.....if you like building headers and want to give it a go.....then by all means do it....make something that is yours and will make you happy. |
Have any photos of that? Sounds interesting. And what did you mean by the 1-3/4" short tube? 34" long doesn't sound so short to me  Also do you have a link to the mysterious online source you used for calculations?
I'm all for easy and fun to drive, and what Modok mentions about the smooth power from idle to redline sounds fantastic if I can achieve that! 
_________________
71 Squareback, 1.7l T4 w/ crank trigger fuel and spark
(Conversion thread https://www.thesamba.com/vw/forum/viewtopic.php?t=732508&highlight= or https://shoptalkforums.com/viewtopic.php?f=1&t=151375&sid=f0542d44a322d290c29d6609fac7f215 )
74 914, 2.0L w/ D-Jet
-Derek |
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oprn
Samba Member
Joined: November 13, 2016
Posts: 12730
Location: Western Canada
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| Posted: Mon Jan 14, 2019 9:35 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| nogoodwithusernames wrote: |
| I'm all for easy and fun to drive, and what Modok mentions about the smooth power from idle to redline sounds fantastic if I can achieve that! |
You can! I did first try and I'm not all that bright!  |
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DeathBySnuSnu
Samba Member
Joined: August 25, 2012
Posts: 1183
Location: MS
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| Posted: Tue Jan 15, 2019 5:13 am Post subject: Re: Let's Talk Exhaust - Building My Own |
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| nogoodwithusernames wrote: |
| DeathBySnuSnu wrote: |
I also built my own headers. I have an odd app and the desire to be different also. Mine wound up being a 4 into 2 split header. It seems to work, but I dont have anything to compare it to. I did get on a wheel dyno once and made good numbers. But since then I have changed a good bit of stuff with the tuning. I have become more concerned with making it fun to drive instead of peak hp on a dyno.
So with a 2387 and fk10.
1-5/8 out of head for the first few inches.
Then an anti reversion can.
Then 1-3/4 short tube (calculated length using online sources) of 34" long from valve.
Then a steep tri-y style (2 into 1) with a 2" collector.
Then a 2-1/2 anti reversion can with a 2" outlet.
It made good numbers.....but nothing to compare it to......would it make better with a store bought header? I will never know (wont fit) and I am happy with the results.
Bottom line.....if you like building headers and want to give it a go.....then by all means do it....make something that is yours and will make you happy. |
Have any photos of that? Sounds interesting. And what did you mean by the 1-3/4" short tube? 34" long doesn't sound so short to me Also do you have a link to the mysterious online source you used for calculations?
I'm all for easy and fun to drive, and what Modok mentions about the smooth power from idle to redline sounds fantastic if I can achieve that! |
Somewhere around here https://www.thesamba.com/vw/forum/viewtopic.php?t=...;start=200
Remember I said I had an odd app.
If I remember right.....Wallace racing......Grumpys......Precision moto.
I even had a phone app or two.
All this has to be adjusted for a VW.
I worked mine towards motorcycle style because of the IR intakes.
_________________
| modok wrote: |
| And look at the SHAPE of the curves, just smooth, like gods own slingshot. . |
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mark tucker
Samba Member
Joined: April 08, 2009
Posts: 23937
Location: SHALIMAR ,FLORIDA
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| Posted: Tue Jan 15, 2019 10:38 am Post subject: Re: Let's Talk Exhaust - Building My Own |
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| were did you get the infrared intakes?? how do they work?? can you see them in the day light?do they glow at night? does it look like your cars are flying? |
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DeathBySnuSnu
Samba Member
Joined: August 25, 2012
Posts: 1183
Location: MS
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| Posted: Thu Jan 17, 2019 5:43 am Post subject: Re: Let's Talk Exhaust - Building My Own |
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| mark tucker wrote: |
| were did you get the infrared intakes?? how do they work?? can you see them in the day light?do they glow at night? does it look like your cars are flying? |
Do seem to work......not to sure about flying.....does look like someone might have been high.....
_________________
| modok wrote: |
| And look at the SHAPE of the curves, just smooth, like gods own slingshot. . |
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oprn
Samba Member
Joined: November 13, 2016
Posts: 12730
Location: Western Canada
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| Posted: Thu Jan 17, 2019 5:50 am Post subject: Re: Let's Talk Exhaust - Building My Own |
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 Not behind the wheel I hope! |
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mark tucker
Samba Member
Joined: April 08, 2009
Posts: 23937
Location: SHALIMAR ,FLORIDA
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| Posted: Thu Jan 17, 2019 10:32 am Post subject: Re: Let's Talk Exhaust - Building My Own |
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| many dont know what IR intakes are. |
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Volks Wagen
Samba Member
Joined: February 13, 2013
Posts: 2926
Location: Germany
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| Posted: Mon Jan 21, 2019 2:39 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| mark tucker wrote: |
| many dont know what IR intakes are. |
Infra red intakes - of course. They suck in infra red light to warm up the engine.
_________________
1973 1303 with AB-motor - sporadic
reconstruction as time permits, 1986 ex-Bundeswehr Doka - on the road again.
I'm definitely, probably, the worlds greatest lover.
Aithníonn ciaróg ciaróg eile. |
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DeathBySnuSnu
Samba Member
Joined: August 25, 2012
Posts: 1183
Location: MS
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| Posted: Mon Jan 21, 2019 6:18 pm Post subject: Re: Let's Talk Exhaust - Building My Own |
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| Volks Wagen wrote: |
| mark tucker wrote: |
| many dont know what IR intakes are. |
Infra red intakes - of course. They suck in infra red light to warm up the engine. |
Glowing.
_________________
| modok wrote: |
| And look at the SHAPE of the curves, just smooth, like gods own slingshot. . |
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