Header Design Using Dynomation 6 & PipeMax 4.7

I think, fingers crossed, this is my final version. Larry Meaux of the Pipemax software liked
version 5 (Tri-Y Design) over version 4 (4 into 1 Design) even thou the dimensions were
not as close for version 5. My stated goal on his forum was a wider torque/horsepower curve
and not peak, I think this is the reason for selecting version 5.

This is not version 6, but version 5 Final. I learned early on that it was not worth perfecting
every version, but take it to the 80% level. Once the I found the one I liked, then go for the
100% level.

I grouped the pics from both versions (Version 5 & Version 5 Final) with similar views
together so you can compare them easily.

Version 5 Below
FP02_HeaderDesign05_01720.jpg
Version 5 Final Below
FP01_HeaderDesign05_Final_01730.jpg

Version 5 Below

FP01_HeaderDesign05_01719.jpg
Version 5 Final Below
FP01_HeaderDesign05_Final_01734.jpg

Version 5 Below

FP01_HeaderDesign05_01721.jpg
Version 5 Final Below
FP01_HeaderDesign05_Final_01735.jpg
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lets hope they do a great job on replicating your intended design
 
I might have something worthy off sending to GP Headers for them to build. I pre-cut
all my straight pieces and then gathered up all the elbows to duplicate the driver side
header. The only piece I didn't have was the final 3.0 inch collector PVC.

I built the duplicate by working on each primary tube from the head out all at the same
time. No telling how many times I have made the trip from one side to the other to compare,
but I figure the distance traveled is about 1/4 mile. How fitting is that !

I have not screwed it all together yet, I wanted to give a day or two before I finalize the design.

FP02_SideToSide_Compare_01741.jpg
FP02_SideToSide_Compare_01739_01740.jpg

I finally had to concede to adding 3/4 inch to one segment shown below. For the comparison
below I had to mirror the first image so all the tubes would be going the same direction. You
will notice that the numbers are backward.

FP02_SideToSide_Compare_01742_01744.jpg
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this custom set of headers on the t-bucket,
will be very interesting for a number of reasons once the headers are built and installed
 
I searched high and low for a couple of hours and this is the best fit gasket I could find. I thought I
found something I could port match, but it's the corners that just won't work. My only idea now is
to buy some 1/8 inch copper sheet and make my own gaskets.

Any other ideas ???

FP01_ExhaustGasketRestingOnHooks_01778.jpg
FP01_ExhaustGasketCenteredOnPort_01777.jpg

I also need to do something quick to send to GP Headers because I shipped them my mockups today.
They will need to have a pattern of the exhaust ports so they can make the primary tubes match exactly.

There will be an megaphone that extends another 17 inches past the short collector in the photos.

FP03_HeadersScrewedTogether_01761.jpg
FP04_HeaderSupportReadyToShip_01769.jpg
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You could use a flush trim router bit to trim the 1/8” copper sheet. Are the heads bolted back on yet?
 
this project and your test results should be both interesting and informative,
and to the few rather observant and knowledgeable members of the hot rod fraternity,
probably 1 out of 10 hot rodders and 1 out of hundreds of tire kickers,
at best, your custom header design and the obvious amount of cash and work involved will be rather obvious,
still youll know you have built something unique,
and it should both sound different and potentially perform, significantly,
better than anything found off the shelf.
 
Are the heads bolted back on yet?
No, not until after I get a completed gasket. If I don't get a copper gasket done in a couple of
days, then I need to something else to send to GP Headers.

I'm thinking any kind of 1/4 inch plastic would work. I have a Regal Plastic supply about 3 miles
from me. I bought some 1/2 inch from them for CCing combustion chambers, ports, etc.

http://www.regalplastic.com/
.
 
Since my off the shelf gaskets didn't work out, I found some copper 2" x .032" x 54" and made
my own gaskets to match my ports.

GP Headers has my mockups now and the copper gaskets should be there by this Tuesday. Right
now I'm disassembling the heads since they are full of copper dust particles from the high speed
grinder I used to open up holes where the exhaust ports where located. For the last 1/16" I used
a cartridge roll to finish with.

I used these to locate the bolt holes. They worked perfect, but drilling a thin material is not very
precise. I wanted some 1/8 copper, but it was not available.

FP02_CopperGasket_01786.jpg
FP02_CopperGasket_01780.jpg
FP02_CopperGasket_01782.jpg
FP02_CopperGasket_01791.jpg
FP02_CopperGasket_01788.jpg
FP02_CopperGasket_01793.jpg
.
 
With the high speed grinder spraying copper dust during the exhaust gasket matching process, it
was obvious that I would need to disassemble the heads and perform a proper cleaning.

FP03_ExhaustPortAfterMatching_01809.jpg

I pulled the flat wire damper from inside the outer spring, lots of particles trapped between
them. Had to use a screwdriver to work the damper out.

FP03_ValveSpringCleaning_01801.jpg

I also wanted to remove any carbon build up on the intake valves that would hurt flow into the
combustion chamber. Interesting that the exhaust valves were easy to clean, but the intakes took
alot more effort to get perfectly clean on the back side. I bought some Chem-Dip, but I found
out results will vary greatly depending on how the carbon buildup was created. I would recommend
that you soak for 3 days at 90° to 100°F if you have time. You can see where I used some Halogen
lights to keep the temps between 110° and 120°F, 24/7. I believe this was a big help getting the
carbon softened up so I could use a SS brush to remove it, did lots of scrubbing to remove ALL
carbon deposits.

This is what I started with ......

FP03_IntakeValvesBeforeClean_01817.jpg

After soaking in Chem-Dip and lots of scrubbing with SS brush.

FP03_ValveCleaning_01805.jpg

After washing the heads in the parts washer, I wanted to remove any deposits from the dirty
solvent that dried in the valve guides, so I used a gun cleaning kit to remove the micro crude
from the valve guides. Used 4 cloths, both sides with some wetting using a silicone spray.

FP03_ValveGuideCleaning_01810.jpg

Easy to see the progression from the first swab to the last. Maybe I should have continued with
several more swabs, but I thought some of the crude was coming from getting the swab into
the guide with the dirt surrounding the entry inside the port

FP03_ValveCleaning_01800.jpg
.
 
great pictures, and the pictures help,
as so many people don,t take the effort to keep used parts clean ,
its obvious your taking the extra effort will pay off in much-increased durability
 
I installed the roll pins that I used for intake gasket matching when the engine was first built. Laid the
gasket on the head and aligned it, then I tapped the gasket with a hammer where the roll pins were
located until it created a hole. This will hold the gasket in the aligned position during assembly.

FP05_IntakeGasketAlignment_01825.jpg

I also did a little trimming of the gasket for even better alignment.

FP05_IntakeGasketAlignment_01827.jpg

The heads are completely assembled and every valve seat has been tested with alcohol for 60 seconds
or longer with zero leaks.

FP05_AssembledAndAlcoholTested_01836.jpg
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GP received my mockup kit on Feb 6th. Zach said they would call when they got them opened
and had a chance to look them over. At some point I sent them another email and asked if they
had any questions. I was nervous that they would start/finish them without a conversation about
what I wanted. Zach said that he wanted to wait until just before they get started so the details
would be fresh in his mind and not confuse details from other customers. That made sense to me.

Well today was the day, Zach called about 8 am this morning. He said I had a lot of details.

I asked him about a completion date, he said they should ship next week !!!

Below is what I sent them, which includes their forum and my additional details in a MS Word document. Plus 19 photos !!!

GP-Headers-Instruction-for-Build.jpg

GP-Header-Fabrication-Reply.jpg
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it will be rather interesting to see what you get back and how well it fits
 
it will be rather interesting to see what you get back and how well it fits
Yes it will !!!

And mean while I am very nervous about the fit and finish until I have them mounted. BUT it
should be an easy one for GP, a full bodied car would be much harder to correctly build from
a mockup.
 
My headers should ship tomorrow, so I should have them this week.

Below is a photo from Zach and GP Headers. They don't have the megaphone or the turnout installed.

IMG_5391.jpg
 
the project seems to be progressing, now we shall see through testing,
if hopefully, improved design made a noticeable and worth the effort improvement,
in theory things should obviously improve
 
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I'm curious how much of change in the carburetor settings will be required with the
new header design. I'm expecting a new round of data collection from the AEM AQ-1
data acquisition system.
 
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