due to not being able to find an exhaust for my 390 in a 94 mustang (did find one, very pricey) I was wondering if anyone ever bought a Mandrel bend kit and built their own headers? If so, what kind of problems did you have.
DSS 331 stroker, AFR 185 heads, Performer rpm 2 intake, Accufab 75 mm race TB, 30lb injectors, 80 mm Pro-M mass air, Extreme energy cam 266.
Anderson ford power pipe the big one, Ford motor sport shorty headers, Bassani x pipe custom cat back with flows, World class T5, center force duel friction clutch.
I have assisted a welder friend of mine build a set of headers for me on another project. The hard part is designing the way the tubes will run, and keeping the lengths close to the same and still have the collectors fit up correctly.
The easiest way is to set the engine in the car, and use welding rod of a decent size as the tube, and bend it around so you can get an idea of how everything will fit together. Stepped headers are more of an issue, but it can be done. You just have to plot out ahead of time how you are going to go from collector to head or vice versa.
It has been my experience that this is not a project for a weekend warrior. The tolerances are very critical between tubes, alignemnt with the heads, clearances to other components. WHich adds up to massive amounts of time.
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2006 Mustang GT in Torch Red
C&L Intake, Evolution Performance Tune, Borla Axle Backs, Hurst Shifter, 4.10's, JBA Long Tubes, Prothane Engine Mounts, Steeda UDPs, FRPP Charge Motion Delete Plates
It is not easy, nor is it quick, but it can be substantially cheaper to do them yourself. You do need to take your time, fit everything, and make sure you leave clearances around spark plugs (nothign worse than not being able to get to a plug without pulling a header), and clearance aroudn the starter.
You can get mandrel bends in several sizes from several places, and cut them to length or section them out witha band saw. Set things up slowly, and tack weld in the car. Pull the header out and finish your welds, but do it in short steps like welding body panels cause tube warps like mad too if overheated.
It is not easy, nor is it quick, but it can be substantially cheaper to do them yourself. You do need to take your time, fit everything, and make sure you leave clearances around spark plugs (nothign worse than not being able to get to a plug without pulling a header), and clearance aroudn the starter.
You can get mandrel bends in several sizes from several places, and cut them to length or section them out witha band saw. Set things up slowly, and tack weld in the car. Pull the header out and finish your welds, but do it in short steps like welding body panels cause tube warps like mad too if overheated.
Doc
Thanks guys, I think I will buy a mandrel bend kit from summit Racing and build my own, hell maybe event patten it.
I was thinking of building my own ,one of my mates has built several sets for chevys he doesn't recon it's too hard just time consuming working it out.
Be sure to post up your results
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Wimblton white 66 coupe C code 289 auto
97 Jeep Wrangler 4.0 auto, lift ,winch,33's etc
04 Holden VY SS 5.7 auto (wifes)
88 KLR 250
DISCLAMER:
Please feel free to ignor all advice/information offered
I could be wrong...... I have been before.
sutphen how is the swap going i am a new member but i have been checking out the posts. i am about to put a 428 scj in my 2003 v6 mustang with a c6. i was wantin to chat a little about what you have done or what you would have done different. oh buy the way call kooks header they built a set of headers for my friends 94 with a 508 big block ford. that is hows going to do mine
Any problems making your own headers? 
