You and I certainly have a different definition for fun and relaxing!!! I've built several sets of headers and I'll never do it again. Last set was a set of 2.125 X 28 x 4 in an early A with the engine set back 8 inches AND torsion bars.

New swear words were invented. The bad thing was I had 12 inch collectors and really needed to be at 18 or a bit more but just didn't have the room.

First, Kudos to everyone who posted pictures of headers they've made. Pretty nice to super nice work. All very impressive. The mandrel from the slug is very clever.


Some good threads on speedtalk about building headers.
Join the speedtalk forum so you can see the pictures. The only e-mails you'll get are those from Speedtalk itself - maybe once a year or two. This one is long but lots of good info in it.
First Time Header Build - Speed talk

Although the guys there prefer 421, we found it too be very difficult in my Barracuda. (We really being Brian Slowe, as he did all the real work) Passenger side is really tight. 4 in 1 would be easier.

Whether or not going for a narrow rpm band, Calvin Elston's perspective on tube size and length off the head is really interesting. If interested, check out his posts in this one
What is (exhaust) Blowdown Length? p.2
and poke around his blog.
http://www.exhausting101.com/?p=37

Another place with building tips is Headers By Ed's website and booklets. If you have the ground clearance, his designs are pretty nice and because they are multi-piece, easy to install.

Good ideals gents i'm likeing the hose clamp /drill hole deal for tacking tubes.

x2

Fastop or the top set for the turbo setup?

I want to do a setup similar to what 69B1 Dart did on my Dart, With them exiting out the fender.

Read over a lot of threads but never see what guys are using for primary length on different setups. What are you guys with setups similar to mine using for primary length on Big block stroker setups? I have a 502 cid with Indys that probably makes 800 and something or so HP and have hooker supercomp fenderwells on it, that I know are killing it.

I was thinking something like 2-2 1/8 dia. with 32-34 inch long pipes?

I mocked up a set using a kit supplied by gp headers, and set the mock ups to them for fabrication in stainless. $1800

https://www.gpheaders.com

https://youtu.be/j9knDsi-td8

https://youtu.be/9s1-AZcPWAA

I fixed it for you

theirs a talented guy!! nice work!!

Yes that's for Ka-BLUE-E the Turbo Avenger.
The black coating has not held up as well as I had hoped. I think my next set will be stainless just so I can skip getting them coated.

I used a couple scrap pieces of aluminum and a couple hose clamps at the joints I wanted to weld to get everything lined up. Worked pretty good.

Here are some headers and crossover pipe I made for my stock 440 big single turbo Dart. What a tight fit everything was

Take a look at plasma applied zirconium dioxide.
Its an industrial process but some places will do small jobs.
Swaintech in the US calls it "white lightning exhaust coating". Seems to have a good rep in turbo circles. I had a set of headers done by them but can't speak to the long term durability personally (sold the headers).
In UK and maybe Aus, Zircotech has several versions of this coating for exhausts. But its more expensive even before shipping.

https://www.zircotec.com/exhaust-coatings/

http://swaintech.com/race-coatings/automotive-coatings/automotive-coatings-price-sheet/

http://swaintech.com/race-coatings/race-coating-descriptions/white-lightning-exhaust-coatings/

I made a set of turbo headers over the summer. I never attempted to make a set before and didn't know what I was getting into over the comments about how difficult they are to make that I read online... I have to say it was 100 times easier than I expected. I bought a header kit to make your own for the pipes/bends and bought some good thick stainless flanges. A few afternoons they were pretty much done.

Just have a lot of bends on hand and it's pretty easy to do. No way I'd pay 2k to have a pair made.

Fastmop were you useing header wrap on the turbo headers or running them unwrap?

No wrap

I seen the same video I believe it was on a Road Kill episode. Basically shows that the header tubes were to big for the engine. It was interesting showing them beating the heck out of a new set of headers.