Well, here's my first attempt at making my own headers. Because of my upper link running alongside my front d-shaft, there was NO room for exhaust (remember, my links ar 2" OD x .5" wall), soooooooo

Fender-well headers were a must. This started life as a standard Headman unit for the RRC/Defender. Cut here, add a few bends there, and voila!

http://pics.montypics.com/greg_davis/2009-06-15/1245113405_headers_001.jpg

http://pics.montypics.com/greg_davis/2009-06-15/1245113465_headers_002.jpg

http://pics.montypics.com/greg_davis/2009-06-15/1245113558_headers_003.jpg

If you've ever seen he Hedman units, the rear tubes are VERY short and the front tubes are pretty long, so one of my goals was to try and get the tubes as close to the same length as possible. Next I'll clean the welds up some and have them high-temp coated.

Tomorrow night I'll tackle the DS one.

Awesome! Great job! Nice to see initiative rather than ambivalence towards what you want to improve/achieve. DIY rather than wait on what might or might not happen...Great rule of thumb.

Now make sure you ceramic coat those sucka's.

--D

Once they're tested out; wanna' make a couple more sets? :D

Definitly get them coated....after only a year mine look like shit!

Methinks they look great. I made a set out of a box of bends for my Triumph so I know how tricky it is. I wish that that ceramic coating had been available over here.

Definitely going ceramic if it's not too expensive. Since the exhaust will run along the outside of each rail, the entire system (cats, pipes, mufflers) will get coated to reduce the heat so the soles of our shoes don't melt. :laughing:

Heading to the garage tonight to try and get the DS done, so wish me luck.

And Extreme, thanks for the offer, but I think I'll pass!:p

After all of that welding did you try to bolt them to the heads? I would be worried that they may not line up after all of the cutting/welding.

Greg, remind me again when you started this project...1994?:D

Be nice 'Tis - You know what it's like with kids......And I think you only have ONE.:p

Yes, once I had everything tacked together, I bolted it on just to make sure. And tonight I went over and attached it with all 8 bolts. Took a little fiddling, but it went on fine.

Didn't get much done tonight: I decided to use the blower to get all the cobwebs, metal shavings, etc. out and found............................................. .................................................. .................................................. .................................................. ......a friggin' 4 1/2 foot long snake skin:eek::eek: in a piece of 2" square tubing. Needless to say, spend 80% of the night rearranging everything and getting as much tubing and stuff off the floor as possible.

At least it will be ready for me next week.

Oh, I also scored some wheels today - 16" aluminum Hutchinson beadlocks.:smokin:

Which means my bolt patern is now decided: 8x6.5" I am sooo excited about those wheels.

Be nice 'Tis - You know what it's like with kids......And I think you only have ONE.:p

Yes, once I had everything tacked together, I bolted it on just to make sure. And tonight I went over and attached it with all 8 bolts. Took a little fiddling, but it went on fine.

Didn't get much done tonight: I decided to use the blower to get all the cobwebs, metal shavings, etc. out and found............................................. .................................................. .................................................. .................................................. ......a friggin' 4 1/2 foot long snake skin:eek::eek: in a piece of 2" square tubing. Needless to say, spend 80% of the night rearranging everything and getting as much tubing and stuff off the floor as possible.

At least it will be ready for me next week.

Oh, I also scored some wheels today - 16" aluminum Hutchinson beadlocks.:smokin:

Which means my bolt patern is now decided: 8x6.5" I am sooo excited about those wheels.

Ha Ha Greg, it just seems like it's been since the dawn of time and yes I can relate bro...although we are up to two now (3 and 5).:)

The headers look GREAT. Thats a project I am scared to try.

I gotta ask though, why in the world would you make your upper link out of .5 wall 2in?

Greg, remind me again when you started this project...1994?:D

Be nice 'Tis - You know what it's like with kids......And I think you only have ONE.:p


LOL, I don't have ANY kids and there is a reason my new truck is called "Someday"!

Greg, I need to call you, I have a client who wants a rear bumper.

"Someday, life will be sweet like rhapsody when I paint my masterpiece" with apologies to Bob Dylan and Bob Weir/Jerry Garcia!

Someday, we will all get our masterpieces painted, I just hope it doesn't require an eternal reward!:flipoff2:

The headers look GREAT. Thats a project I am scared to try.

I gotta ask though, why in the world would you make your upper link out of .5 wall 2in?


Thanks for the compliment. I used the same material on all my links. My truck is a PIG so I wanted to make sure I never ended up with bent links.


PT, just lemme know. I've got a sweet deal going on over at D-Web. Call me if you need to. 704-577-0532. And thanks for thinking of me.

And yes, one day our canvases WILL be covered.

'Tis, somehow you snuck one in on me. Mine are 4 and 8 now!:eek: It goes SOOO fast. I guess that's why I don't resent the time they take - before long they won't even want me around.:bawling:

I ordered the rest of my exhaust components today: Dynomax high-flow cats and mufflers, clamps, collector flanges, and some tubing - all in SS.:D