OK so I might be crazy.

I recently purchased ported W5 heads for my 408 stroker that is going in my '70 Cuda. The exhaust ports have been opened up to rectangles that are very close to big block size. W5 headers from TTI are kindof out of my price range...but I know how to weld and am not afraid of hard work and I want larger primaries...say 1 3/4" or 1 7/8".

I can buy a set of W5 header flanges for $30. Would it be possible to get a set of big block headers and some exhaust tubing and weld up big block headers to fit a W5 headed small block? Has anyone ever tried this? I guess I am more concerned about starter / motor mount interference than anything...

you could do it, but at that point, why not just build custom headers?

while on the surface it seems like if you could mate the big block tubes with the w5 flanges, you would have a set of hybrid headers that fit the motor and your chassis.....I would be concerned that your big block headers were made for a specific chassis with an engine who's exhaust ports are at a specific height and angle in the engine bay.

are your small block exhaust ports in the same spot in the engine bay as a big block exhaust port, and at the same angle? I don't know the answer, but I'm thinking no.

I tried to modify my SB headers for better starter/steering link clearance, looks easy but it was such a PIA
Now I hav drivers side that I ended up putting back to original configuration but looks like cr@p (one tube)
Soo looking bac all I really did was waste a LOT of time and ended up with the same ol thing Would not hav tried at all but already hav a new set waiting for wen these headers turn to dust or is it rust.
Just my

While I do not have the expertise to comment on your sanity I will say that an individual who is not afraid of hard work & who knows how to weld(I'm envious ) should go ahead & tackle it & when you are successful you'll be much better off because of it.

Thanks for all the input! I love moparts! everyone is so much nicer here than other places...

I have found some bigger primary tube headers for a small block that I am considering buying for ~$200...it looks like I will still have to weld on some flanges and collectors but that won't be bad at all and better than me spending the $650 for the tti headers.

I would love to make my own custom headers but I am trying to save some money and take a little less time. I definitely agree that the angle and locations of the ports is different. I still believe it could be done though. Since a small block is narrower than a big block I think a few inches of straight rectangular tubing at whatever angle necessary could connect big block headers in their installed position to the ported w5 heads...I even thought about buying big block flanges and w5 flanges and then leaving the big block headers unmolested and making an adapter piece instead, If only I had some cheap big block headers lying around...I do have some 1 7/8" headers on my '68 Charger...a pain to remove with the engine in but then I could do some trial fitting...I'll let you all know what I make time for...Thanks again for entertaining my craziness!

No, not crazy at all. I don't remember where I got it and now I don't know where it is, (loaned out but not returned) is the plastic header mock up kit. Its a kit that comes with plastic tubes with all kinds of bends, angles whatever you need to mock up a set of headers from just about any motor in any car. The pieces just snap together and you use whatever bends etc til you have a set that fits and theres your jig just waiting for you to get welding on the real pipes. Check Summit or Jegs as they may have the kit. Thw wildest set I ever did was a 440 in a 89 Conquest and it still took less then a day to do it, good luck.

Hey, it never hurts to try, if it gets too frustrating, you can always buy a set. But that said, you may come up with something better, and end up in the header business! You never know.......