I Modified The MAC Mustang Longtubes ... Fastsc92 showed the way

MrBlvd

Registered User
After much deliberation, I figured what the heyl if he can do it there is no reason I can't either ... especially since he did such a great job of documenting his project ;) . Since some of the following pictures are rather frightening, I must tell you this is the first time I've ever welded anything ... I taught myself how to use the MIG, TIG, plasma cutter, and torch equipment here at work and completed this over the past three weeks in the eavenings and on weekends. I spent one Saturday afternoon practicing with the MIG and the following Saturday afternoon with the TIG before using either on the actual headers. I purchasead some exhaust tubing at Advance for practice as I new I needed practice to keep from burning thru the thin tubing.

Prior to using the welding equipment, I attempted to create flare joints by machining a "plug" that I could drive into the tubing and by use of an exhaust tubing expander. This approach failed misserably ... the #5 primary looks horrible before I cleaned everything up. I did not attempt to flare the #6 and I was actually pleased with how this looked when I was done.

Rather than weldup a fixture like fastsc92 did, I purchased an extra set of stock manifolds and then made use of the spare heads I currently have (soon to be ported with valve job!). I installed the headers and the stock manifold and observed them "side by side". This allong with fastsc92's pictures and some photos I took under the car helped me to visualize what needed to be done.
 

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more picts

Like I said, using the flare approach did not work out like I expected :eek:
 

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looking better

taking the time to learn how to weld definately worked to my advantage and made life much easier
 

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finished product looks OK for a first timer

On the passenger side I took a little different approach ... I turned the #1 primary out so it would curve around the starter and then I brought it back in to line up with the tube running up to the flange.

Now, I have yet to test fit them on the car and may very well be in for some additional adjustments ... I realize I should have just tacked them, test fit, and then finish welding. To be honest, I was having such fun learning to weld that I just went for it and figured if I had to rework ... so be it

I will post an udpate with pictures and any additional adjustments required
 

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Additional photos of interest

I used these to help visualize what needed to be done
 

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A couple more photos of passenger side

This shows the starter adjustment a little better
 

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I'm glad some of my pics helped, but what pipe did you use? It looks like you used non-mandrel bends and did a lot of fudging to get the parts to line up correctly together. I'd be a little concerned about flow since the pipe doesn't make too many smooth transitions....
 
Understood

Yea .. like I said some of it looks a little rough ... I purchased two 180 mandrel bends from summitt ... the #5 definately could be a lot smoother ... I realize these will not be the most efficient but I had fun, learned a lot, and did not shell out $600 for headers with oversized primaries (in my humble opinion) ..

I was the brunt of many jokes at work (which is just fine by me, I would rather bring joy than sorrow to this earth even at my expense) .... anyway, I told them that I was going for a flatter torque curve as opposed to making peak torque at a given rpm

I'm going to run a pool at work kinda like they do at March Madness ... how many weeks (days or even hours:eek: ) before the first leak shows up and/or before the first piece falls off:D

If I do another set ... they will be much much nicer
 
David...you are the man! I remember when you started talking about fabbing headers and it just seemed complicated to me...and well you DID IT! Nice work for sure...and like you said saved ya some pennies!

Oh, and we need to get to gether sometime so I can get your wrench back to ya! Don't want ya to think I'm keeping it ;) :D .

Can't wait to see them installed...and if you need help when you plan to tackle this job, you better call my ~~~! :eek: :D

-Tim
 
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