My Long Tube header build - Page 3 - Toyota Yaris Forums

Bluevitz-rs · 11-19-2012, 11:07 AM

cool

xnamerxx · 11-19-2012, 04:38 PM

Just picked this up from the shop

I need to do some finish work on it but overall everything came out better than I hoped.

tooter · 11-19-2012, 06:22 PM

Looks really neatol!

Will you put the runners inside the flange holes?

xnamerxx · 11-19-2012, 06:32 PM

sorta I'm either going to flare the tube or cut and wedge the pipe in the flange. I matched the flange port diameter to that of the gasket so I don't induce any extra sharp edges that will mess up the initial shockwave from the exhaust.

I'm going to speak with the welder and see if I can get this started tonight.

tooter · 11-19-2012, 07:24 PM

I had a similar issue building the manifold, and had little "shelves" machined into edges of the ports to hold the runners in alignment while they were being welded up. It worked great because the weld filled in the shelf and covered it up smoothly...

...leaving the inside relatively clean.

xnamerxx · 11-19-2012, 09:11 PM

All cleaned up and ready to be welded on :)

xnamerxx · 11-21-2012, 12:05 AM

Well its time for me to post a real update

I now understand why Richard Holdener went with a 4-1 design its so much easier to package and get the correct length out of. I'm about 1/3 to about a 1/2 of the way finished with the primaries. Thank god the welder who is helping me out had experience building motorcycle race exhausts because I made some bone headed mistakes. All in all my primaries are longer than the stock primaries and my secondaries will be cake on top of that. So to keep you guys tided over here is a picture of the first tube being tacked in place.

tooter · 11-21-2012, 01:01 AM

It's so exciting to see your project begin to take shape.

It's like creating a work of functional art!

What are you using to cut the tubing so cleanly?

xnamerxx · 11-21-2012, 01:25 AM

I'm a bit fortunate to have access to shop equipment but I've been cutting everything with a band saw, grinder, or belt sander.

So in order to get the clean cuts after I make the initial cut I deburr the edge of the tube both inside and out and it makes that nice clean lines, makes it way easier to weld as well apparently too. I can't take all the credit though, I'm getting lots of help from the welder on how to properly work with tubing.

I'm amazing on how much work it is to make these pipes, its been quite fun, but quite a bit of work. I wish I took some more pictures after I got the collector on but it was getting late and I needed to home. Hopefully I'll get the other 2 pipes welded up tomorrow and a initial test fit to see if everything's kosher.

Something I thought was a bit funny but my primaries right now on my tri-y header are longer than the primaries on the stock header and I still have about 2 feet of secondaries to add.

Bluevitz-rs · 11-21-2012, 01:30 AM

are you going to dyno the results before and after?

tooter · 11-21-2012, 02:26 AM

Quote:

Originally Posted by xnamerxx

I'm a bit fortunate to have access to shop equipment but I've been cutting everything with a band saw, grinder, or belt sander.

So in order to get the clean cuts after I make the initial cut I deburr the edge of the tube both inside and out and it makes that nice clean lines, makes it way easier to weld as well apparently too. I can't take all the credit though, I'm getting lots of help from the welder on how to properly work with tubing.

I'm amazing on how much work it is to make these pipes, its been quite fun, but quite a bit of work. I wish I took some more pictures after I got the collector on but it was getting late and I needed to home. Hopefully I'll get the other 2 pipes welded up tomorrow and a initial test fit to see if everything's kosher.

Something I thought was a bit funny but my primaries right now on my tri-y header are longer than the primaries on the stock header and I still have about 2 feet of secondaries to add.

If yours going to be this long?

(just joking

)

xnamerxx · 11-21-2012, 10:28 AM

I have dyno results from when I was stock, but I'm going to dyno it against a DC header after its been vetted.

LOL its going to be close but thats all I'm going to say

Another taste ;)

tooter · 11-21-2012, 02:30 PM

Is your header going to have an 02 sensor bung? I was thinking of chopping my WR header in half and adding a couple of straight tubes to lengthen it.

MBSPE · 11-21-2012, 02:46 PM

nice work

xnamerxx · 11-21-2012, 04:04 PM

It will but I'm a ways from being able to weld the bung in place. It might be difficult to extend the primary length for the WR header which is what you would want to do.

Thanks :)

tooter · 11-21-2012, 06:04 PM

I only was thinking about lengthening the secondaries as its easier.

The logical place to cut would be at the first welded joint up from the bung where everything is pointing straight at each other.

Jason@SportsCar · 11-21-2012, 06:09 PM

Quote:

Originally Posted by xnamerxx

I have dyno results from when I was stock, but I'm going to dyno it against a DC header after its been vetted.

LOL its going to be close but thats all I'm going to say

Another taste ;)

Good stuff, cant wait to see dyno numbers.

xnamerxx · 11-21-2012, 06:10 PM

I don't think you'll see any benefits to doing so just because the primaries are far more important than the secondaries for base scavenging.

What I would do is cut the point before the primaries join get a u bend SS in the right diameter cut and bend it so the pipes sit on top of each other like a 4-1 and pull them out about 18-30"s and use the existing merges as a way to terminate the pipes.

11-21-2012, 02:46 PM	#50
MBSPE Custom Exhaust Drives: Yaris Sedan Join Date: Nov 2012 Location: Pasadena, MD Posts: 15	nice work __________________ -Greg @ MBS Custom exhaust fabrication! www.mandrelbend.com www.mandrelbendingsolutions.com

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11-19-2012, 11:07 AM	#37
Bluevitz-rs 1NZ-6spd View User's Garage Drives: '05 6-Spd Vitz RS Join Date: Oct 2008 Location: Oshawa, Ontario, Canada Posts: 2,967	cool

11-19-2012, 04:38 PM	#38
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	Just picked this up from the shop I need to do some finish work on it but overall everything came out better than I hoped.

11-19-2012, 06:22 PM	#39
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	Looks really neatol! Will you put the runners inside the flange holes?

11-19-2012, 06:32 PM	#40
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	sorta I'm either going to flare the tube or cut and wedge the pipe in the flange. I matched the flange port diameter to that of the gasket so I don't induce any extra sharp edges that will mess up the initial shockwave from the exhaust. I'm going to speak with the welder and see if I can get this started tonight.

11-19-2012, 07:24 PM	#41
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	I had a similar issue building the manifold, and had little "shelves" machined into edges of the ports to hold the runners in alignment while they were being welded up. It worked great because the weld filled in the shelf and covered it up smoothly... ...leaving the inside relatively clean.

11-19-2012, 09:11 PM	#42
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	All cleaned up and ready to be welded on :)

11-21-2012, 12:05 AM	#43
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	Well its time for me to post a real update I now understand why Richard Holdener went with a 4-1 design its so much easier to package and get the correct length out of. I'm about 1/3 to about a 1/2 of the way finished with the primaries. Thank god the welder who is helping me out had experience building motorcycle race exhausts because I made some bone headed mistakes. All in all my primaries are longer than the stock primaries and my secondaries will be cake on top of that. So to keep you guys tided over here is a picture of the first tube being tacked in place.

11-21-2012, 01:01 AM	#44
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	It's so exciting to see your project begin to take shape. It's like creating a work of functional art! What are you using to cut the tubing so cleanly?

11-21-2012, 01:25 AM	#45
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	I'm a bit fortunate to have access to shop equipment but I've been cutting everything with a band saw, grinder, or belt sander. So in order to get the clean cuts after I make the initial cut I deburr the edge of the tube both inside and out and it makes that nice clean lines, makes it way easier to weld as well apparently too. I can't take all the credit though, I'm getting lots of help from the welder on how to properly work with tubing. I'm amazing on how much work it is to make these pipes, its been quite fun, but quite a bit of work. I wish I took some more pictures after I got the collector on but it was getting late and I needed to home. Hopefully I'll get the other 2 pipes welded up tomorrow and a initial test fit to see if everything's kosher. Something I thought was a bit funny but my primaries right now on my tri-y header are longer than the primaries on the stock header and I still have about 2 feet of secondaries to add.

11-21-2012, 01:30 AM	#46
Bluevitz-rs 1NZ-6spd View User's Garage Drives: '05 6-Spd Vitz RS Join Date: Oct 2008 Location: Oshawa, Ontario, Canada Posts: 2,967	are you going to dyno the results before and after?

11-21-2012, 10:28 AM	#48
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	I have dyno results from when I was stock, but I'm going to dyno it against a DC header after its been vetted. LOL its going to be close but thats all I'm going to say Another taste ;)

11-21-2012, 02:30 PM	#49
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	Is your header going to have an 02 sensor bung? I was thinking of chopping my WR header in half and adding a couple of straight tubes to lengthen it.

11-21-2012, 04:04 PM	#51
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	It will but I'm a ways from being able to weld the bung in place. It might be difficult to extend the primary length for the WR header which is what you would want to do. Thanks :)

11-21-2012, 06:04 PM	#52
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	I only was thinking about lengthening the secondaries as its easier. The logical place to cut would be at the first welded joint up from the bung where everything is pointing straight at each other.

11-21-2012, 06:10 PM	#54
xnamerxx 0-60 in slow Drives: light blue liftback Join Date: Aug 2009 Location: so cal Posts: 926	I don't think you'll see any benefits to doing so just because the primaries are far more important than the secondaries for base scavenging. What I would do is cut the point before the primaries join get a u bend SS in the right diameter cut and bend it so the pipes sit on top of each other like a 4-1 and pull them out about 18-30"s and use the existing merges as a way to terminate the pipes.