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I know most are not foolish to go down this path, but I've never been called smart.
I am building a set of long tube headers for my 408w and I purchased all the stuff from Stainless Headers. Is it normal to have the collectors this large? The 4 tubes go into the collector about .5". Do you just trim the collector to fit?
I do have an email out to Stainless Headers to see what they say.
They stated that since some builds the tube lengths are not all the exact length and therefore with the larger opening, it allows you to modify accordingly. I guess making one larger is better than making it smaller. I will probably trim it down a few inches when I get there. I'm not looking forward to cutting that in my band saw.
This is not a slip fit collector, but I'm certain you knew that.
I edited my response. Exactly equal length primary tubes are hard to achieve and only really needed for the last bit of HP in a race motor. I would trim the collector to where it matches the pipes. Also, its hard to explain - but heat and mash (form) the pipe ends into a "cross" and weld 'em up so they flow better into the collector.
Last edited by gstrom99; Dec 30, 2025 at 10:33 AM.
Great link. I will spend some time on that site later this evening.
I did find my other collectors and they fit perfectly. Certainly better than the ones I got at Stainless Headers. I guess if you were a pro at this, you probably want something you can modify to fit your build. I am not building a race engine, just something to tow my 5th wheel. I wanted some long tube headers since my Gibson shorties are well over 20 year old and they have done a fairly good job. I could not find a long tube header that would match my desires or wallet. If I am going to spend $1,500, I might as well learn a new skill and design something that I can work around.
I was low on Argon so I went to the welding shop to get my bottle swapped out. I should have thought about a different CLR so the tubes can run a bit closer. I ordered some 4" CLR bends. They won't be here until the first of the week. I'm not going to get these done by the end of the week, which was my goal. Not the first time that has happened.
Much better fit! I'd send the loose one(s) back. TIG welding? I'm pretty good with MIG but I've only dabbled with TIG once or twice. I'd like to get a cheap(er) one and try to get good for delicate or alum/stainless projects.
Last edited by gstrom99; Dec 31, 2025 at 07:35 AM.
I learned gas welding in high school and tig welding is a lot like that. I have no training with any other type of welding, but like most things in life, it's a skill you learn and the more you try it, the better things look. I am fortunate to live in a time where they got a lot of free videos online. They certainly make it look easy enough to say 'I can do that'. I have more skills in grinding.
I looked at that website and the collector transition is less with the ones that fit better. They indicate that it effects flow. I am certain it does, but for my purpose and skills, it will be fine.
I'm on the passengers side now. I'm not done on the drivers side but pretty much done for what I can do. I'm hoping to get the passengers side to the same place. Once the 4" CLR bends come in, I will finish them. Then comes taking the tubes apart and finish welding the entire tube. Then weld it all back together. Yeah, it will be purged.
When I made the header for my (Kawaski powered) formula car, I welded on tabs (cotter pins to secure them) so the pipes could be snaked into the chassis and then have the collector fitted. Quite a bit of cut/fit/cut some more/ and weld - short curled bits to get it to be equal length and come out where I needed. TIG would've worked better, maybe, but you use what you have. I could never buy what I made, and it was satisfying in the end.
Be sure to post more pics.
Last edited by gstrom99; Dec 31, 2025 at 10:00 AM.
Given the two choices, I would choose the MIG over the TIG for welding headers. Either process is capable of producing good looking welds in the hands of the right person. There are probaby going to be places on headers where it is going to be tough to get a torch, a rod, and your eyeballs all existing in the same place. It's not not a bad thing to challenge yourself though.
Part of building your own stuff, you can plan ahead. Although, I have not finished welded anything [just tacked], I don't think there is one place that will be difficult t reach with my tig welder. I have a MIG welder, but the thing I dislike most is that in order to have an arc to melt metal, you have to add more rod. With TIG, you can melt the metal and add rod if needed. It's not for everyone, but you need more skills [ie practice] to TIG weld. Certainly not the type of welding for today's 'I got to have it now' world.
I plan on leak testing each pipe before welding the pipes to the flange.
You lost me at 'hands of the right person.' I got a grinder to hide my skills.
So far, the task is just time consuming. The real challenge is when I mount the headers in the truck. I will not post the words that I will use if they don't fix.
As a mechanic, performance is not the main goal. It's having more access for future maintenance. Easy to remove the starter, easy to remove the transmission, etc.
I've never had to weld up a set of headers, so TIG welding them might not be as difficult as it would seem. Each process has its pros and cons. Though TIG is by far my favorite process, there are places that I actually prefer to use stick over any of the other processes. "In the hands of the right person" isn't meant to be a jab at anyone, I was just saying that there are people who can put down a good looking weld with about any process you put in front of them. And grinding is a very good skill to have. I have seen more things destroyed beyond repair with a grinder than I ever have a welder.
I did not think you were jabbing anyone. I would never say I got skills. I've seen people with skills and it takes practice to be at their level. I just don't have the time to develop the skills for anyone to think I'm good. If I was rich, I would probably sublet the entire thing.
When I am done, I will be able to say I've done that before. That is what makes life worth living.
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