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How2 Extractors

scratchbuild custom headers

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#1 mopar68

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Posted 27 February 2012 - 03:05 PM

Here I will show you how to scratchbuild an extractor. Use this tutorial as a guide only- you can choose your own size/shape/whatever. The same techniques can be used to create all sorts of types of extractors/headers. It's a lot easier than it looks and a whole lotta fun so don't be afraid to try it! Just experiment and have fun :)
This extractor isn't a replica of any particular 1:1, it's just based off the many I've seen in magazines/on the net/other peoples' builds etc...
Rito enough talk, let's get building-

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Here are all the materials/tools I used to make this extractor-
0.5mm styrene sheet
1.6mm styrene rod
3.2mm styrene rod
hobby knife; No. 11 blade
pinvise; 1mm, 1.5mm bits
sanding stick
dremel grinding bit
lighter
styrene cement
rubber band
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First of all, and the most important thing, is to plan how you are going to make you extractor. What size does the flange/pipes need to be? Is it going to clear chassis rails/steering boxes/whatever else? A little planning ahead will save alot of headaches in the long run. Test fitting is also very important- check the fit of every piece you make as the part comes together.

Alright, let's really get building :P

Using the 0.5mm sheet, we need to cut the flange out. If you have the kit header handy, you might be able to use it to get the correct size. Next is to drill 1.5mm holes where you want the pipes coming out (not a bad idea to use your 1mm bit to drill pilot holes first). This will make things alot easier rather than just gluing the pipes straight to the flange.

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Okay, pipes. to make a bend in rod, I use a lighter. I know some people can bend rod without heat, but I just can't. Well not without breaking it anyway :lol: . The trick here is to use just enough heat to be able to bend the rod easily; just a second right above the flame is enough for rod this small. Too much heat and it will begin to pit, or of course catch fire. Also, allow plenty of room from the end of the rod where you make your bend. If you make it too close, the tip of the rod will expand and it won't look so pretty. Neither will it fit in the holes in the flange-
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First bend-

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Also a good idea to mark where you want your bends before you bend them. And remember to test fit.

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Now cut the excess, but make sure you leave plenty of length.

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Continue using this same method to make the rest of the pipes. Oh don't forget to test fit them as you go :P .

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As you can see, there is a fair bit of excess rod sticking through the other side of the flange, this will be trimmed away a little later.

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#2 mopar68

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Posted 27 February 2012 - 03:06 PM

So now you will have something a little like-

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Put the pipes in one last time, grab your rubber band and add a touch of glue.

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While that's drying, get your 3.2mm rod and your pinvise. We're going to make the tip (collector I think they call it). I drilled a 1mm pilot hole in the end, then used my 1.5mm bit to open it up. Hobby knife was carefully used to open it further. You probably can't tell from the picture, but I also sanded the end of the rod into a somewhat cone shape.

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Desired length was then cut off, and cleaned up a little with the sanding stick.

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Make sure you give the glue plenty of time to dry. When it is, take the rubber band off and mark out where you want the pipes to collect into the tip. This is where you will cut them.

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Clean the cut up a little, then sand the ends of the pipes down a little, into a little bit of a point. The pic will explain-

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Now glue your tip on. Starting to look like an extractor now.

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Edited by mopar68, 27 February 2012 - 03:07 PM.


#3 mopar68

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Posted 27 February 2012 - 03:08 PM

Time to grab that Dremel bit. You can shape the flange however you want, I chose to keep it simple.

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Finish it off by cutting off that excess 1.6mm rod sticking out the back of the flange and finishing with the sanding stick. Depending how cleanly everything went together, the transition from pipes to the tip might only need a quick sand. Otherwise, just use a little putty.

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And there you go, a custom extractor. Now you just have to make the other side :lol:
Well I hope this has helped a bit, feel free to post up any questions, corrections, or comments. Hate mail can be PM'd :P
B)


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#4 Frank

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Posted 27 February 2012 - 03:53 PM

Zac thanks for the great tutorial, very easy to follow. I am going to have a go at building a set.

#5 vintagestang

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Posted 27 February 2012 - 05:12 PM

I will try this too.

#6 Greg Busby

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Posted 27 February 2012 - 07:11 PM

So will I

#7 mopar68

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Posted 28 February 2012 - 03:58 AM

Thanks fellas, hope it helps someone a little ;)
Oh I forgot to mention, you can use a jewlers file instead of a dremel bit. When I done this I didn't have any so I made do :D

#8 crazyjim

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Posted 28 February 2012 - 04:07 AM

Most excellent, Zac. I was trying a very similar method just yesterday on some chopper pipes. You make it look easy. Did you use Evergreen or Plastrut rod? I don't know if the brand would it make a difference.

#9 mopar68

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Posted 28 February 2012 - 04:49 AM

Thanks Jim :D I used Evergreen here, I'm not sure if there's a difference either, don't suppose so.

#10 wraith

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Posted 28 February 2012 - 05:22 AM

Very nice tutoral! Someday soon I will be trying this on my 40 Ford pickup!

#11 Jantrix

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Posted 28 February 2012 - 05:38 AM

Very good tutorial. But .........the real trick is getting the second one to match.

#12 george 53

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Posted 28 February 2012 - 06:18 AM

WOw Zak, when you said EXTRACTORS, I was thinkin of the vents that were on the upper front fenders of Trans Am pontiacs! Over here, we call those pipes headers. Never ever heard of 'em called anything but. But hey, I guess your right, caz that's CERTAINLY what they do! THANKS for the tute, it's GREAT! :lol: :D ;)

#13 mopar68

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Posted 28 February 2012 - 06:35 AM

Thanks again guys.
Yea true Rob, I'm still working on that part :lol:
Here's a set of not-quite-yet finished turbo headers, almost mirrored :)

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Over here, we call those pipes headers.

Thanks George, they're often known as either name down here. 'Extractors' sounds a bit tougher I guess :P

#14 george 53

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Posted 28 February 2012 - 07:26 AM

Zac, ALL the guys here,from Oz can do INCREDIBLE stuff with plastic. I've often wondered if there IS somethin in the water!!! Maybe livein in paradise helps. Our Brother Stump(Greg Armour) certainly lives there, caz I've see pictures!!!!!! seems like ALL you guys got "mad skills" ,to coin a phrase. :lol: :D :) ;)

#15 MikeMc

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Posted 28 February 2012 - 03:20 PM

Agree with George.....Those are easy to build and look KILLER B) B)

#16 mopar68

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Posted 29 February 2012 - 02:25 AM

Wow thank you George, I really appreciate that :)
Thanks again everyone, glad I've inspired a few people to try it. Have fun! 8)

#17 hotrod59f100

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Posted 29 February 2012 - 08:06 AM

I'm gonna try this. Thanks

#18 pharr7226

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Posted 01 March 2012 - 04:59 AM

Great tutorial... well written, easy to understand, and good pictures.

#19 Roncla

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Posted 10 March 2012 - 03:14 AM

Thanks for posting this tutorial Zac. Its very easy to follow and inspirational.

#20 BKcustoms

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Posted 16 March 2012 - 03:11 PM

Thanks for posting this! I just used your technique on my 69 Nova project and it worked great.