opps it warped..any fixes??

[zen]

ok..1st go at homemade headers....used thick wall water pipe bends and pipe..1uz into range rover so headers had to be tight to block and short with exit straight down between 3 and 4..its 4 into 1 with the pipes from 1 ans 2 longer than 3 and 4 by loads..(still gotta be better than the stock !)

1 went fine, the other has warped lenght wise along the flange( 5mm!!! ahhh),outer edges folding in towards tube side..

it looks like it will bolt up,but am quite conserned it will leak or snap studs..will it help to cut flange between pipes or will this make it worse??or maybe cut into pipes bolt it up and reweld pipes together taking up the gap with weld,thus allowing the flange to lie flat???
do not want to remake!

thanks

 

[markstoys]

If they are shaped right, you could try bolting the two sides together. If the bolts suck them down flat fairly easily, then you might be OK just putting them on the car.

If you put them together the flanges would look like this--(), right?

If you really want the flanges flat, you could put spacers near the ends when you bolt them up, so the flange bends the other way as you tighten it--like this )( you would propbably need to bend them back beyond 5mm for them to come out straight. How much more is a trial and error kind of thing. I would go 5, then 7, and just keep going until they are straight. I hope you can visualize what I am talking about.


To prevent warping in the future, use thinner tubes--they need less heat for welding (less heat = less warping). And bolt them together (or at least to something strong and flat) when you weld them.



I made these, and bolted them together when I welded them. The flange stayed really flat.

Mark

 

[zen]

thanks will try that ....nice headers..

 

[litldv8]

pull them off and take them to a machine shop and get them to machine flat (probably on a belt sander)
neil

 

[XR8tt]

Bolt them to a flat steel plate and go over with tig ??
Always weld manifolds on a thick plate RSJ or whatever..
Just drill holes in plate and tack bolt's to back so you don't have to use two spanners..Drill the outer holes on manifold bigger to allow for expansion or it will warp with heat, when it can't expand..
A thin cut between each primary on flange helps also..
These methods are used on turbo manifolds where there's heaps of heat..

 

[edz]

Bolt them to a flat steel plate and go over with tig ??
Always weld manifolds on a thick plate RSJ or whatever..
Just drill holes in plate and tack bolt's to back so you don't have to use two spanners..Drill the outer holes on manifold bigger to allow for expansion or it will warp with heat, when it can't expand..
A thin cut between each primary on flange helps also..
These methods are used on turbo manifolds where there's heaps of heat..

This was the channel I worked on to reduce warpage, cut the joiners between each pair and see if that helps, otherwise take it to a machine/metal fab shop as suggested and get them to flatten it on a big belt sander.