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How to get dents out of headers

Discussion in 'The Hokey Ass Message Board' started by 64 Thunderbolt, Mar 12, 2013.

  1. Ralph
    Joined: Jan 8, 2004
    Posts: 295


    Brilliant! The dents are almost always on the outside for clearance, so the hole's on the inside unseen. Just happen to have a set of nice Big Block Chevy headers to try this on. Thanks Jimmy2car!
  2. roder1935
    Joined: Nov 30, 2010
    Posts: 68


    My kids take music lessons from a lady who repairs brass insterments she has all kinds of tools to reach in curves and bends she can take a crushed brass horn like a tuba and make it look as good as new so you may try checking out your music store but they have to be set up to fix brass horn good luck
  3. The hard part is finding a woman that can suck that bearing through the header tube! :D:eek::D
  4. 64 Thunderbolt
    Joined: Feb 8, 2011
    Posts: 277

    64 Thunderbolt

    It's funny you say this. The guy I got them off of was a PDR guy & he was the one that suggested the water & deep freezer trick.
    He couldn't get to the dents to PDR them!
  5. jcapps
    Joined: Dec 30, 2008
    Posts: 473

    from SoCal

    Coating will probably get damaged at engine break in anyway. I never coat headers till after break in
  6. rustang
    Joined: Sep 10, 2009
    Posts: 710


    +1.... I'm guessing that the metal will be stretched where the guy hammered on the header, it is amazing he did not knock the coating off to this point, unless these are just some shallow dents...

    Regarding the ball bearings, if your luck would be like mine, I would end up getting the dent out, but then the ball bearing would get stuck... :)
  7. That's all well and good for brass but the steel tubing the headers are made from is considerably harder than brass.
  8. 37 caddy
    Joined: Mar 4, 2010
    Posts: 275

    37 caddy
    from PEI Canada

    What they do is drop the big bearing in from the collector end,propably wont go in past the flange any way,fill the tube with more bearings,then you have a way to push the ball past the dent,when it passes the dent it should be able to fall out the way it came in,kinda works like a big flexible push rod?,hard to explain but you should be able to visualize it in your mind. Harvey
  9. mohead1
    Joined: Jan 18, 2013
    Posts: 553


    I agree w the drill opposite and reweld, Ive done that before. Ive heard about the air pressure and heat deal, but depending on the coating, the red hot torch heat will certainly mess up the coating. Sounds like you got the crap end of that deal.....fix em right and recoat....there goes the budget......ouch
  10. Hot Rods Ta Hell
    Joined: Apr 20, 2008
    Posts: 3,893

    Hot Rods Ta Hell

    Yeah, if nothing works and you have to make a repair then recoat them, you might try the drill from behind method along with a slide hammer stud gun studs from the outside while someone pushes from the inside with a punch.
  11. mrconcdid
    Joined: Aug 31, 2010
    Posts: 1,157

    from Florida

    find or make some wooden balls the exact size of the tube, then drive it through the header, with a hammer you will need several balls to push the first one through, the wooden ball stands the best chance to not harm the finish and still repair the dimple/dent.
    Otherwise the drill from the back side and punch out option would be my next attempt.

  12. dreracecar
    Joined: Aug 27, 2009
    Posts: 2,847

    from so-cal

    Whatever you do , do not wrap the headers as they will rot out the tubes faster than throwing them in the ocean

    Put the same dents on the other header and claim its a speed secret to help tune and balence exhaust flow to compensate for the varience for the number of bends and overal lenth of the tube as it comes out of the collecter @ 43.2 mph
    Last edited: Mar 13, 2013
  13. 64 Thunderbolt
    Joined: Feb 8, 2011
    Posts: 277

    64 Thunderbolt

    It wouldn't rot with the coating though.
  14. no55mad
    Joined: Dec 15, 2006
    Posts: 1,807

    from nipomo, ca

    ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ x2
  15. dreracecar
    Joined: Aug 27, 2009
    Posts: 2,847

    from so-cal

    It does, If you dont beleive me , call a header comany and ask them

    Pro race teams do it because the headers dont last long enough before they change or switch them to rust out
  16. falcongeorge
    Joined: Aug 26, 2010
    Posts: 18,341

    from BC

    Quick question. Have you tried installing these headers on your fairlane yet? You are sure gonna feel silly if you spend a bunch of time removing those dents, only to find that you have to put them right back again to get them to fit in the car. Not saying this is gonna happen, but I would sure check carefully before I hammered them all out...

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