header flange

[Hammer Head]

Anyone have a diagram so I can cut my own header flanges? I know I could always get some header gaskets & go from there but I figured maybe I could just print them up & save a little cash. I'm pretty bored & feel like trying my hand at making a set of headers.

[87wildside]

For what, the 4.3?

[Hammer Head]

Yep.. that's the forum I'm in, right? heh

[87wildside]

Well since it's in the V6 forum, um, dont you have a set of cast sbc manifolds? Just trace them and take the front cylinder off one side and the rear off the other

[Hammer Head]

Yea, but I need the total length of the head & exhaust port centers. If I have at least that I can do the tracing w/ the sbc manifold.

[Mikz86TA]

You need the triangle flat flange that goes on the y-pipe with the 3 holes in it?

[Hammer Head]

No, I have those already. I just need a diagram of the flange on the cylinder head side.

[Hammer Head]

https://www.headersbyed.com/chev.htm that's the part that I'm going to make. I know it's a picture & by lookin at it I could wing it but I'd feel more comfortable w/ actual dimentions.

[87wildside]

This sucks, got gaskets with my headers and bought the copper ones so I have an extra set of paper gaskets, Wanna guess where they are? With my truck.............in NJ. If I can get up there this week or next I'll send 'em to ya.

[Hammer Head]

Just PM'd ya about it.

[Hammer Head]

wait.. you said Jersey.. I forgot to say YO! haha

[87wildside]

lmao.....hehe

[Hammer Head]

I've got at least four sets of headers sitting around here & two sets of cast manifolds.. might as well make use of something. I think I'll cut up the pontiac 3 into 1 headers, they're for a V8 & the center exhaust port expels both center cylinders. Anyways, they're something like 1-3/4" dumping into a 3" collector. I have bungs sitting here doing absolutely nothing & I'll need to extend the O2 wires. I also know the tubing size is problably too big for a stock 4.3 but I'm really bored. What's the worst that happens? I trash a set of headers?

[87wildside]

I do crap like this all the time. Even if you mess them up you are still geting some practice at fabricating,

[extreme gmc]

i got some paper gaskets i can hook you up with. pm me with you contact info & maybe we can hook up this week since i am off work...

[jswag5]

man, if ud have caught me a week ago i would have traced my gibson flanges for ya

[Dogsofjune]

<sniff> Wished I could make my own headers.

Thought about havin' a set made for the Toy......I'm thinkin' GarretT28?

[jswag5]

also on the subject, them gibsons put out a sweet exhaust tone, well worth the 360 bucks!

[87wildside]

<sniff> Wished I could make my own headers.

Thought about havin' a set made for the Toy......I'm thinkin' GarretT28?
Haha....I know you couldn't leave it alone!

[Dogsofjune]

It's tempting, hehe

[Hammer Head]

Hey Extremegmc, thanks but I've got a set on the way pretty soon. DOJ, I've got plenty of toys (tools), no job & wayyy too much time on my hands. Jswag, I like the quality of the Gibsons but like I just said.. no job.. no funds to just drop $360 on some headers when I can do it for maybe a few $$. Only thing I need to find now is some O2 sensor connectors so I can make some O2 extenders for the long tubes I plan on making & maybe some header paint if I can't find ..wait, scratch that I've got 3 cans of black BBQ grille paint, hahaha. That stuffs good to like 1500 degrees or something.... So, does anyone have both sides to the O2 sensor connector w/ a pigtail? heh

[87wildside]

How are they coming along? We want pics!

[Hammer Head]

Remember how I called you *****in about my pnematic die grinder not grindin fast enough? Well, I ordered an electric a Chicago Electric from Habor Freight (& no.. that's not a plug for them) in hopes it'll be faster.. it should be here tomorrow.. maybe. Anyways.. maybe next week I can finish the flanges. I've got them roughed out, but that's about it. I've been pretty busy w/ interviews lately & come friday I'll be out of town until tues or wends.

[87wildside]

I have a Habor Freight down the street. Hate that store, go in for one thing and leave with everything but what I went in for....lol

[Hammer Head]

I also ordered up a gasket prep kit.. basically a right angle die grinder w/ a sanding disc... less than $20 & that's the cheapest price I've seen compared to at least 45-(get this..lmao) 375! WTF? Oh..ummm... what size is the O2 bung? I can't seem to find my bung holes..hah. I know they're metric.

[Hammer Head]

Habor freight custom service says between 10-14 days until I get that stuff.. I think it will make my task of trying to get to the drivers side manifold easier if I pull my vacuum booster & swap it for the hydro-boost unit I've got waiting to go in (it's gotta go in anyway for the LSx swap for clearance issues.. I would like to be able to change my plugs eventually..hah). But then I'd need to make my lines from the unit to the pump & steering box..

[Hammer Head]

Ok, I tried out the electric die grinder this afternoon to see what she'd do.. wow, it sure beats the pneumatic grinder (if space is available). Here's a couple pix of how they are now. Still not finished, still only roughed out.. but you can see the lines I plan on takin them to. Also I still need to grind out more in the holes because I'd like the pipe to go through the flange. BTW, I drilled & bolted the two flanges together so they both have the same 'fit'. Here's the pix..

[87wildside]

Looking damn good! I also like when it goes through the flange. What is that, 5/16 or 3/8?

[Hammer Head]

I think I measured it out at 5/16".. but it could be 1/4" hahaha.

[plant.one]

I have a Habor Freight down the street. Hate that store, go in for one thing and leave with everything but what I went in for....lol

Kid in a candy store huh?

I have the same problem when i go in there.. i have to leave my credit/debit cards at home and only take soo much cash or i'd buy the whole damn place!

Also have a Kitt's Tools not far from here that rocks my socks.

sorry.. didnt mean to hijack.. just couldnt resist :D

[droopy89]

So Hammerhead, when are you gonna go into business and make us headers for cheap?

[Hammer Head]

As soon as I can save up $60k & get a mandrel tubing bender or if I can get hold of 50+ sets of used headers for free. haha. Honestly, if you can find the OEM shorty headers they're almost as good as JBA's or Gibsons & a lot cheaper. I see them on ebay every so often for a decent price.

[droopy89]

Only 60k, theyres loans and mortgages for that kind of money

[Hammer Head]

Yea, but you need a job for one of those.. a good job.

[droopy89]

O yea, sorry bout that, kinda forgot

[Hammer Head]

haha.. no problem.

[87wildside]

What's this about OEM headers?

[Hammer Head]

They're almost just as good as aftermarket shorties & better than the cast manifolds. I can't seem to find a picture but they were usually on trucks. I think they were on a few cars, too.

[87wildside]

Full size trucks? Damn, if I knew that I would have got them and saved a few hundred.

[Hammer Head]

Yea, they were made for the 4.3. I don't remember exactly what had them.. could have been in a camaro or one of the metric (aka. G) bodies. 3.8 GN's had OEM headers.

[Hammer Head]

Well, I had some time to work on this some more. Got the flanges finished off & opened the gaskets up to 1.5".. used a hole saw for both, but finalized the flanges w/ the grinder. Set a few tubes in place but I need to redo the #4 tube.. I can see it'll hit the control arm. I tacked it a little more then I wanted to.. I wanted to see how much room there actually was. Anyways, here's some pix of the progress so far...

[droopy89]

lookin good so far

[87wildside]

I want to see pics or your monkey throw-up :D

[Hammer Head]

Ok, Eric, you asked for it & now you're gonna get it. I took a pic of it just for you, so you can see my crappy welds. Yea, I finally made my way back out & set some time down to more or less finish up at least the passenger side header. I changed the design from what I was originally gonna do.. you can tell that by lookin at the pix up top & then these.. to a short design instead of long tubes. ..only took me about 4 mths to get goin.. hmm maybe it was all the heat.. yea, I'll blame the heat. Anyways, on w/ some pix..

[87wildside]

Holy ****! Other then the welds they look good. Sorry Jason, I wanted to lie but I couldn't do it.

[Hammer Head]

I think I may just grind down some of the welds & 'cheat' by using some muffler/exhaust sealant. Then just spray some header.. or BBQ grill paint over them. Thanks for the compliment Eric! I think I'll need all the positive self-esteem when I try & tackle the driver's header. Should be alright, I draw myself little pictures & try my best to base what I do off them.. but we all know that real life is sometimes a different picture & we need to bull**** a little to get things to all work out. ;)

[87wildside]

Just grind them down most of the way. They will be fine. I draw pictures too....haha. Nothing ever looks like the drawling, good thing for me.

[Hammer Head]

The reason I'm thinkin about the sealant is there's pin holes on most of the welds once they get ground down. When I tried to fill them all that would happen is I'd burn through the pipe & just all around made a bigger mess. ..*****, *****, *****..

[Mikz86TA]

Just work on the welding skills a bit. You can do it. Im not gonna lie to you tho. Im no welder but my guess is technique and settings on the equipment to match your technique.

[Hammer Head]

Yea, it is all technique & settings.. Personally, I think it's a bit too hot for the 16ga tubing but I'm going off what Lincoln recommended. I know I get much better results when I hold the gun at the 45 degrees I should be holdin it at.. haha. I also know it's not going to be the cleanest weld because I'm not using any shielding gas.

[Hammer Head]

Well, I went back out there again this afternoon & more or less finished them up. I just need to grind them, cut the excess off the pipes on the flange & trim out a little of the flange. I really hope the driver's side fits. If not I'll just have to bump 'em a little w/ the hammers. Here's a few more pix.. oh, forming (or tryin to) collectors is a PITA.

[Mikz86TA]

you putting a whistle tip inside em?

[Hammer Head]

Wooo-WooOOOO.. hahaha.. no

[87wildside]

Impressive. What size are the collectors?

[Hammer Head]

1.5" od tubes feedin into 3" collectors.