Hi,
I never have posted before on a forum, but I had some pics of my turbo headers I just finished tacking up, so I figured I would show it. It is made of 321 16g stainless u-bends that were cut in segments. A total of 3 different radii were used to get the smooth flow and equal length. The picture of the merge collector on the previous link reminded me of what I built so I thought I would share some pics for once. Check out the mock-up tubes, They are corigated cardboard 1-5/8 and hold there shape when bent. Simply cut all 6 to the same length and plan out your routing. Build each tube in segments replacing the mock up tubes as you go. It actually took many hours to get the flow of the tubes to be what I wanted, but was fun and challenging. The merge collector was formed from 15 degree tubes and spliced together, the second half was hand formed over a steel form CNC machined from a solid model I created in Pro-e. I will polish all the tacked tubes, break it apart and finish welding it together leaving the heat zones like on the finished merge collector. I hope you enjoy the pictures, maybe I will get around to posting other parts for my car that I have fabricated.