Making headers

[Mixalz]

I know this has been asked before but the Photobucket issues are making finding examples impossible. Basically I'm trying to fabricate some headers from aluminium wire and am struggling. I was wondering if anyone had a WIP photo to show the process they used (aluminium wire or any other alternative).

These are the ones I'm trying to replicate

https://s1.promotionsupplies.com/ebay/cxmotorsports/images/turbo_kit/cxm-TRB-Kit-Supra-Mk4-CB-CAR-2.jpg

Thanks

[John Pol]

I use solder and aluminium tubbing for the collector solder is easier to bend

[crazyjim]

I cut lengths of aluminum wire and CA glue together at one end.  The start forming.

[fiatboy]

There is a company in the UK, "Cornwall Model Boats", that makes styrene rod that is easily  bendable and stays set.  I've ordered some from them but have not tried it yet.  I read about this on this online forum.  I can say that it is not expensive at all, even considering shipping.  

[Mixalz]

Cheers. Haven't had much bench time recently but will try the solder first since that is locally available.

[Alix Bernard]

I recently made a set for a dragster. These kind of spooked me because not only were they attached to the heads but they had to exit the full body through slots. I drilled the heads out to accept the solder and temporarily glued one in place(made it a bit longer at the cylinder head so it slid into the hole) Once adjusted in place the remainders were fairly easy. The primaries were glued together and a small strap went across all 4 pipes to strengthen the set .The valve covers cover the holes and the longer stubs of the headers.

Edited November 1, 2017 by Alix Bernard

[landman]

These were made pretty much like Alix describes above. The ends are shink sleeves over a short piece of tubing. The shrink sleeves are too thick though.

[BigTallDad]

If you're using solder, make sure it isn't acid-core flux.

[crazyjim]

There is a company in the UK, "Cornwall Model Boats", that makes styrene rod that is easily  bendable and stays set.  I've ordered some from them but have not tried it yet.  I read about this on this online forum.  I can say that it is not expensive at all, even considering shipping.  

Would have a part number?  I looked and only found Evergreen rod.  is that it?

[landman]

If you're using solder, make sure it isn't acid-core flux.

OOps! That's what I used Ray. What will happen?

[BigTallDad]

Hopefully, the acid won't slowly leak out and mess up your paint or glue connections. Next time, use a solid-core (no flux, be it acid or resin) solder.