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  1. #1
    Official RnS Addict Big Joe's Avatar
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    DIY Headers

    I'm thinking about making my own exhaust headers/six branch manifold for my Zodiac (straight six engine)
    Ive found these bends on the web and they look like they should do the job and they do tube to match

    https://www.fhbrundle.co.uk/groups/2...le_Elbows_Tees


    My battle plan is to make them on the bench using a spare head as a jig (yes I have one)

    The hard bit is that the MK3 CCZ has a half round recess in the head that the original pipe manifold fits into, so I need to make up D blocks with steel plates welded to them (this is how its usually done on these engines) or maybe use one long half round bar to fill the half round recess.
    I havent measured the diameter accurately but it looks to be 1 & 3/4 inch and I cant find bar in that diameter.

    Any thoughts?

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  3. #2
    Welding Guru
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    The finished manifold will be quite heavy using those bends, have you looked at mandrel bends on ebay. There are loads on there that might be an option

  4. #3
    Official RnS Addict Big Joe's Avatar
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    Quote Originally Posted by weldtech View Post
    The finished manifold will be quite heavy using those bends, have you looked at mandrel bends on ebay. There are loads on there that might be an option
    Thanks, I didn't think about the weight I will look at the eBay bends

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  6. #4
    richard rawlplug Torment's Avatar
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    Whengparts may be able to help with flanges.


    The Oddlot Drag Racing Team...havin fun is usual
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    your not drunk enough if you can lie on the floor without holding on..

  7. #5
    Stroker Kustom Jim's Avatar
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    I converted a 1600 four branch to fit my MKII Consul (1979 ish) By god what a job making up the half round bits for the heads was. Fortunately I did them at work. If I had my time again I'd find a way to use the stock manifold bit that bolts to head hot diggety no doubt.

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  9. #6
    Official RnS Addict mygasser's Avatar
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    Quote Originally Posted by Kustom Jim View Post
    I converted a 1600 four branch to fit my MKII Consul (1979 ish) By god what a job making up the half round bits for the heads was. Fortunately I did them at work. If I had my time again I'd find a way to use the stock manifold bit that bolts to head hot diggety no doubt.
    that's what i'd do too, it's already the right shape to do the job so no point reinventing the wheel.
    neil.
    need a job done on your project? i may be able to help.

  10. #7
    Official RnS Addict Big Joe's Avatar
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    Quote Originally Posted by Kustom Jim View Post
    I converted a 1600 four branch to fit my MKII Consul (1979 ish) By god what a job making up the half round bits for the heads was. Fortunately I did them at work. If I had my time again I'd find a way to use the stock manifold bit that bolts to head hot diggety no doubt.
    I did think of that, but the stock manifold is a tube (I'm sure you both know that) I did think of using a steel bar of the same diameter and boring the holes in that....

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    Official RnS Addict trevd's Avatar
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    can you not use the original manifold tube and open up the original holes and bore them all the way through to take tubes? i could make the D parts for you but it would be cheaper to modify what you have and less chance of leaks.

  12. #9
    Official RnS Addict Big Joe's Avatar
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    Quote Originally Posted by trevd View Post
    can you not use the original manifold tube and open up the original holes and bore them all the way through to take tubes? i could make the D parts for you but it would be cheaper to modify what you have and less chance of leaks.
    I did think about that but the steelwork is nearly sixty years old and just a little bit corroded. I'm thinking along the lines of using a length os one and three quarter inch bar and boring (or having an engineer shop bore) the holes for the ports and welding the tubes onto that.
    The reason that I was thinking about the D blocks and plates is because that's how it was done in the old days..

  13. #10
    Official RnS Addict mygasser's Avatar
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    on the plus side if you went for the 'd' blocks you'd only need to buy a round bar half the length to start with, lol.
    neil.
    need a job done on your project? i may be able to help.

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