Ok so here's the deal. I've searched and googled and youtubed. Ive found info on building your own headers but I'm thinking of building headers for my 62 bel air with a 409. I'm looking for any advice and tips on this. I know it's kinda specific, but a 58 to 64 chevy with a 348 or 409 should be pretty close. I'm thinking the good thing about it is the spark plugs are above the exhaust ports, so trying to work around them won't be an issue like in a small block. I think I could pull it off, looking for help. Thanks
They make “ header kits” that have bends straights and the like. I would start with one of those. Bones
Look for pictures online or in catalogs and decide which style you would like. Do you want a fenderwell header or under the car exit? Do you want a block hugger/shorty? A long 4 tube? maybe a Tri-y? Do you need a big tube performance oriented header or just a street header for a mild 409? The frame on the '58-64 Chevys makes the exhaust system a little more difficult. IIRC, Hedman used to make a header where the collectors actually pointed outward under the frame instead of straight back like most headers. Speedway has U-bends and J-bends as well as a box of random bends. I think there are several sources for flanges. I would use 1 7/8" or 2" tube for a 409, maybe 2"- 2 1/8" if it's a high rpm drag racer or a 500" stroker. Building headers used to be a magical specialty but these days lots of talented car builders do it themselves, go for it.
The only advice I can give you is to make your cuts straight (I use a chop saw) and get a good picture in your mind as to how you want them to run. Tack them together in the car if you have two pipes running close together and they need to be welded tack them good and remove them from the car weld them and put them back.
Beautiful work Marty. Do you remember where the flanges and collectors came from? The OP could use them.
Thanks guys, the customer furnished the flanges, I got the bends and collectors from Patriot, that was about 10 years ago.
Nice job rite there...was that a kit type or from scratch w u bends and watnot Sent from my SM-G960U using Tapatalk
http://www.348-409.com/forum/threads/wilson-header-mfg.37289/ Have you check with this guy, I have a set and they fit great.
In the '70's my cousin bought a stripped out SS396 with no engine. He put a 409/425 in it and I got the job of building the headers. Looked like a can of fishing worms all crawling out at the same time.
Hellsgate hot rods sells the flanges, They also sell the bends and a "basic cut and fit" header kit. Chevrolet 348-409 Exhaust Flange - Hells Gate Hot Rods
Wow. Those headers look REALLY nice. But I hate to say it, but the price is why I'm considering building my own. I have looked around and that price is about right. I know nothing about a 409 is cheap, but I have been saving and collecting parts and money for this build for quite a while. Im putting the motor together right now, and I'm saving for an intake. I've always wanted to try building headers, so I figured why not.
Small tip. I made a set of headers this summer for my project and made a little tool to help mark my cut lines when cutting bends to fit. It's just a block cut to fit the inside radius of the mandrel bends I was using with a piece of bent welding rod planted in the center.
I bought Speedway bends and straights. We made our collector out of a piece of 4 inch pipe and a hammer and a torch. Not as slick as the pair above but they work and no one that I could find made Pontiac fenderwell headers. At least not that I could afford.
In all reality, that was a pretty simple set to make, compared to lying on your back doing under car headers. That's tough on an old man !
Gus ... just do it man. I built these from scratch for my Buick Nailhead and they came out great, all MIG welded and sanded, then heat coated.
Good idea on the tool, even simpler than others I have seen. Now I need to spend a day and make several, for the various tube sizes and radius bends.
Tri-Y's I am building for the coupster. Flanges from an old set of headers, bends from Speedway and the collectors are made from a piece of 2 1/2" tube and a Speedway collector flange. (I would suggest buying an extra bend or two. Shipping is right pricey when all you need is one more.) I made a jig similar to Paulz's and used 3M green tape, tightly wrapped, to hold the pieces together when I was fitting them up. Witness marks help. When I was ready to weld I cut a couple of 1/4"-3/8' wide strips of the tape out across the joint and tacked.
I made these for the 351 Cleveland in my 29. Just a kit from Speedway and flanges from another set of Hooker Headers that I had setting around. Ceramic coated them. Muffler inserts inside of the extended turnouts. Not quiet but not loud. Depends how far I bury the right foot.
Here are some on mr 409 himself 33 willy's. Rob Walden's gasser Sent from my SM-A505U using The H.A.M.B. mobile app
My Dad has a 32 he's putting a 409 in and I'm hoping he lets me recreate some vintage look Hedman hedders. I've got the original lower extensions from some Hedman's, so I'd probably make the top section as tri-Y. I'll be watching this thread for tips.
Check out the S.P.D. Exhaust sight. Best bends I've ever bought. They aren't thin on the outside of the bends. I use a drop arm band saw but it's not a H.F. P.O.S. and I had a pal (Gilbertson Machine) machine the gap in the drop gate (where the blade finishes) opening exactly the same on both sides of the blade. Makes for perfect cuts every time. Quick and easy no fussing around. Yes you can do it but your first set won't be your best set. Plan ahead before starting. My best advice if it's worth anything is this, If you don't have a Tig welder then Gas Weld them. Mig welds in general look like KRAP and have way to much fall through.
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