Custome Gen4/5 S/S Header Build

[SRT09]

So after doing more and more thinking on what changes were going to do on the head. I took a look at my current exhaust header combo M&M headers and my own custom 3" exhaust. I think I'm going to jump into building a custom set of headers for my car in hopes of getting the most out of the car. Pulled the old headers out and I think there is a lot of room for improvement. I've fabricated a lot of exhaust systems and headers just never for the Viper so ill try to document it as well as I can

Think after taking a look at the merge quality on my old headers etc there should be some good room for improvements!

Here are a couple of Pics I took of the build so far still waiting on my material to come in from various suppliers. Let me say one thing that material alone is a huge cost phone Burns or somewhere and ask for a quality S/S 5 into 1 Merge collector and expect to pay over $1000 just for a set of high flow merge collectors.

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Looks like a lot of areas to pick up some improvement

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Inside view of one of the formed merge collectors

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Inside view of one of the formed merge collectors other angle

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[SRT09]

Pics of a manifold I just build for my other car recently.

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[SRT09]

So this is the start of building the fixtures for the Gen 4/5 headers.

transferring flange bolt pattern to Fixture

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Dbl checking flange pattern with old headers

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[About2bite]

Awesome! How are you bending the tubing? $1000 for a pair of ss collectors? wow that's crazy. What grade stainless? How much time you have invested and how much time do you plan to invest in these headers?

 

[SRT09]

You can only buy the S/S already mandrel bent and cut and fit it together. Yeah a well designed 5 into 1 merge collector is a lot of work and time. I will update this thread as I have just received over $2000 worth of stainless, and I still don't have header flanges and some other flanges I need to have custom made for me. Getting the firing pattern where I want it and equal length as close to possible is going to add a lot of time to the fabrication but I think it will be more then worth while.

 

[SRT09]

Got a bunch more work done still waiting for my custom Header flanges to arrive Wow a lot of work so far, I'll update some pics soon once I'm on a real computer!

 

[SRT09]

Working on some new CnC'd Header Flanges for the Gen 4/5 application

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[SRT09]

Some pics while getting the collectors finished off!

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[SRT09]

Made some huge progress today I think these headers flanges turned out way better then even my wildest expectations!

Starting with a big chunk of 304

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Doing work!

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Bling!

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[SRT09]

A couple more pics!

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[Green viper 1]

These look nice

 

[SRT09]

Thanks hoping to get some more work done on them this weekend

 

[SRT09]

Finally got a chance to work on this again over the weekend and am happy to say the Drivers side is built and test for and the passenger side is built awaiting test fitment when I get back in town

 

[SRT09]

Quick pic just pulled them out of the fixture to test fit before final welding!

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[SRT09]

To answer some PM's these are a stepped header design long primary's as you can probably tell from the pic. I will be trying a few combos to see which is the best overall!

 

[SRT09]

Not much extra room to play around with

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[v10viperbox]

Quick pic just pulled them out of the fixture to test fit before final welding!

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That is almost too pretty to bolt onto the car. I have never seen a 5 tube flange like that it must have cost a fortune to have made with the inner peak.

 

[SRT09]

That is almost too pretty to bolt onto the car. I have never seen a 5 tube flange like that it must have cost a fortune to have made with the inner peak.

Thanks its a parallel merge collector with a reverse cone should be a real smooth transition. In a header one if not the most import HP factors is the collector design then Primary length and then size.

 

[SRT09]

Some pics of welding as the headers are in for coating as we speak

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Couple of pics of the test fitting before coating!

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[Torquemonster]

Great to see someone doing it right. That's how a header should be done on these cars, nice work!

 

[SRT09]

Thanks just waiting on the coaters then I get to try them out

 

[Camfab]

Looks like you did a great job! Did you buy those collectors from Burns or did you make them yourself?

 

[SRT09]

Thanks and no nothing was bought from burns everything from the flanges to dbl slip fits was done in house!

 

[Nine Ball]

Very talented, wow!

 

[SRT09]

Sorry for no update but was sick and out of town a lot for work

 

[SRT09]

Hopefully things work out and I get a chance to get these things installed and build the exhaust in the next week or so

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