AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
6/20/21 9:20 p.m.

Jeebus, where does the time go? Here's another header tube to flange joint, before:

and after weld / flap disc:

GaryC83
GaryC83 New Reader
6/22/21 12:43 a.m.

In reply to AngryCorvair (Forum Supporter) :

Looks good. Another tip, though a touch late now, apologies, is I usually recess my tubing about an 1/16" down into the flange that has a healthy bevel on it to start. Gives a place for the weld to sit, and makes for a fast quick & easy operation to go at it with a burr bit and then cleanup with some sanding lollipops on a grinder. Makes for a pretty quick cleaning up of the welds in general. That and doing silicon bronze on the outside is the best advice I can give after having done a slew of headers and learning the hard way. 

 

I usually clean up my flanges on a big 20" disc sander after they've been fully welded, then take them to a surface plate with some 80 grit to final true them up. The easier cheaper way is a long board and 80 grit.  I use dykem, but you can even scribble with sharpie then block to reveal the lows.  

These aren't the best pics or headers I've done...but gives a good idea. 

 

Anyway, great work. Love the project!  Keep it up. 

Patrick (Forum Supporter)
Patrick (Forum Supporter) MegaDork
6/22/21 7:25 a.m.

Cool, your headers should be done for the 2024 challenge, then maybe wiring by 2032

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
6/26/21 6:01 p.m.

I've finally got one header that actually lives up to the name 4-2-1:

welds are still cooling. When I can grab it without burning myself, I'm bolting it in place and leaving it there for a while.

preach (fs)
preach (fs) HalfDork
6/27/21 5:41 a.m.

I like the header but all I can see is the glove. Well played.

03Panther
03Panther UltraDork
6/27/21 3:45 p.m.
preach (fs) said:

I like the header but all I can see is the glove. Well played.

I would have missed the glove, if ya hadn't mentioned it!

03Panther
03Panther UltraDork
6/27/21 3:49 p.m.

In reply to AngryCorvair (Forum Supporter) :

Good to see the headers coming along. 
On the bikes, it was always called a 4 - to  - 1... wouldn't a a 4 - 2 - 1 translate to a tri - y?laugh

(I don't remember which one your building )

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
6/27/21 4:47 p.m.

In reply to 03Panther :

Yes, 4-2-1 is same as tri-Y

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
6/27/21 6:59 p.m.

symmetry is overrated

Dusterbd13-michael (Forum Supporter)
Dusterbd13-michael (Forum Supporter) MegaDork
6/27/21 7:47 p.m.

In reply to AngryCorvair (Forum Supporter) :

Heat them cherry red woth oxy acetylene and a rosebud tip. Bend collector end oh so slightly. Boom. Symmetrical. 

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
7/4/21 3:24 p.m.


Last whiteboard update was 11/29.  time to get this train back on track.

gumby
gumby Dork
7/4/21 5:45 p.m.

Put away tools. I am adding that to my list for tomorrow; the actual tomorrow, not "tomorrow"

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
8/4/21 8:42 p.m.

2022

Mr_Asa
Mr_Asa PowerDork
8/4/21 9:04 p.m.

In reply to AngryCorvair (Forum Supporter) :

No bueno :-(

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
8/4/21 9:32 p.m.

In reply to Mr_Asa :

Life gets in the way sometimes. I spent a lot of time doing stuff with my family this summer, plus a few out-of-town work trips, keeping up on daily drivers' maintenance, etc. It is what it is. I'm still picking away a little at a time.

preach (fs)
preach (fs) HalfDork
8/4/21 11:41 p.m.
AngryCorvair (Forum Supporter) said:

In reply to Mr_Asa :

Life gets in the way sometimes. 

I wish mine was only sometimes. Mine seems all the time, plus I have a ton of deferred maintenance on the house.

I cannot wait for more of this but take care of you and yours AC.

maschinenbau
maschinenbau UltraDork
8/5/21 6:54 a.m.

I keep hitting this button but the pain won't go away. Please continue to bless us with more Monzora updates. 

Patrick (Forum Supporter)
Patrick (Forum Supporter) MegaDork
8/5/21 9:39 a.m.

Stampie
Stampie MegaDork
8/5/21 10:05 a.m.

In reply to Patrick (Forum Supporter) :

Sometimes I feel sorry for Angry. He can't help that he's old and slow. 

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
8/5/21 10:31 a.m.

Those last two posts are exactly what I was hoping for. Life is better with some good-natured abuse. 

AWSX1686 (Forum Supporter)
AWSX1686 (Forum Supporter) UltraDork
8/5/21 12:10 p.m.

Slow and steady wins the race right? They don't mention the haggling along the way! laugh Keep it up!

DeadSkunk  (Warren)
DeadSkunk (Warren) UltimaDork
8/5/21 12:17 p.m.
Stampie said:

In reply to Patrick (Forum Supporter) :

Sometimes I feel sorry for Angry. He can't help that he's old and slow. 

Younger and faster than me. Don't take the crap, Angry!

TVR Scott
TVR Scott SuperDork
8/5/21 12:28 p.m.

Unfair call on the header work.  I mean he is trying to TIG weld dirt to baked-in oil.  A man's gotta take some time to do the job right.

Stampie
Stampie MegaDork
8/5/21 12:28 p.m.

In reply to DeadSkunk (Warren) :

Age is a mindset.  He's older than you.

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
8/5/21 12:30 p.m.

Currently working on coolant tube routing. I bought a 10 foot stick of 1-1/2" exhaust pipe, will use leftover pieces of 1-5/8" from the header project for the bends, and cut sections of the OE hoses for connections and couplings.

Trying to make bends as gradual as possible within other packaging constraints. Started by marking and drilling with step bit:

then cobbled some pieces to get from engine to the under-floor tunnel that used to hold original heater duct and controls / wiring:

Then cut a pass-thru from forward end of tunnel to front suspension area:

Made some spacers from scraps and zip-tied long straight pipes together, and screwed a couple pieces of 1.5" angle in place as temporary supports:

will continue to piece things together as life allows. Waiting on parts to R&R timing belt, water pump, and front LCAs on AK1's Forester, which will be #1 priority when they arrive.

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