header design and build - 460 Ford Forum
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post #1 of 17 (permalink) Old 01-17-2013, 02:16 PM Thread Starter
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header design and build

Thinking of building my own headers for my 2002mustang with a 460 in it.

Header style and design is a question i have. Along with some fab questions.

I posted three pics of completely different header design. Two look very restrictive and teh maddog headers look simple, clean and free flowing.

I plan on using a motor plate and a trans crossmember (no midplate)

I also thought about picking up a "weld your own kit" to 1. save cash 2. get the experience.

I have a mig welder with gas at the house.

Anyone have tips or tricks to not screw this up , or should i just spend the money of already build headers- if i make my own i planned to flow the design of the maddog one since they look the easiest and look less restrictive.




all of these are around the same pricing.
maddog headers





Hooker supercomp

D&D autospec
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post #2 of 17 (permalink) Old 01-17-2013, 02:17 PM Thread Starter
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yes i stole those pics! LOL
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post #3 of 17 (permalink) Old 01-17-2013, 02:45 PM
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If you enjoy fabricating stuff, it's a great way to save a few bucks and have some fun. It also makes you feel good to say "oh, I built them" when people ask where you got your headers.

You don't really need anything more than a mig and an angle grinder with a cut-off wheel, although a band saw is nice to have.

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post #4 of 17 (permalink) Old 01-17-2013, 02:49 PM Thread Starter
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Carl, do you have any opinions on the three header designs i posted?

I know what i atheistically like, just looking for some opinions also
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post #5 of 17 (permalink) Old 01-17-2013, 03:43 PM
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Originally Posted by frank13 View Post
Carl, do you have any opinions on the three header designs i posted?

I know what i atheistically like, just looking for some opinions also
Generally, you want as much straight pipe as possible before the first bend, as few bends as possible, and as equal length as possible...equal length being more important than fewer bends. The chassis will more often than not dictate how close to perfect you can get.

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post #6 of 17 (permalink) Old 01-17-2013, 04:31 PM
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I you are going to fab your own, you'll also need several of the triangular shaped fabrication magnets to hold the tubes in alignment until they can be tacked. The smaller ones will fit into tighter places.
Rob

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post #7 of 17 (permalink) Old 01-17-2013, 06:40 PM
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There's also the tri-Y design that goes four into two then into one.

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post #8 of 17 (permalink) Old 01-18-2013, 05:35 PM
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Optimum primary tube length and diameter depends on the RPM range the engine will see most of it's time in.
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post #9 of 17 (permalink) Old 01-19-2013, 06:21 PM
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header

i have a 1994 mustang with 557 with p51 head ,i have put a set of hooker header.
i have upgrade with with kooks header 5502 is a horor or nightmare
the left side the tube are too long to clear shock tower and the right side it impossible to bolt the tube on cylinder 2

if i have to go back ,my first choice is hooker header
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post #10 of 17 (permalink) Old 01-19-2013, 10:58 PM
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I don't think anyone makes ones to work with a stick so you will more than likely need to build your own our modify a set. I have done three sets of customs now and definitely got better results on the second set and third set than the first. I am planning on buying a tig welder and starting to do more of them I enjoy the challenge and to have ones custom built is usually $1500+ I can't see charging that kinda money so gonna do them cheaper. I say go ahead and build your own, the worst part of doing them with a Mig is grinding the welds down of you want a clean look our you could just wrap them.

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post #11 of 17 (permalink) Old 01-20-2013, 02:43 PM
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IMO wraping them is a good idea any way.
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post #12 of 17 (permalink) Old 01-20-2013, 04:02 PM Thread Starter
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ok guys,

Decided to build my own:

How to build Headers for a 2002 Mustang - My way...
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post #13 of 17 (permalink) Old 01-20-2013, 05:01 PM
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Header fab video tutorial:

http://www.stainlessheaders.com/headerfabrication

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post #14 of 17 (permalink) Old 01-20-2013, 05:12 PM Thread Starter
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watched all six already, its where I go the pvc idea
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post #15 of 17 (permalink) Old 01-20-2013, 07:46 PM
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Header design & build

You should get in touch with Eddie Henemen at Headers by Ed in Minnesota. 612-729-2802. He's got all the peices and can advise you all the way. He helped me with mine, now I'm on my third set. You just can't buy a set of headers that are as good as what you can build, you may doubt that right now but you'll be glad you did it afterwards.
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