What's new
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

'72 K5 - Greg's @MightAsWellK5 Build

This is the build description. I will improve this later. (GB)
Overview Gallery Discussion
2015.11.02 - UPDATE! - 7 DOWN....1 TO GO!!!

UPS dropped of the latest package from Cone Engineering.... 4 more 180-degree bends

IMG_7511.jpg



I'm just hoping that I don't actually need FIVE... I hate paying more for shipping charges, then for the actual parts! :haha:

Yesterday I started chopping up those new U-Bends and slowly swapped those segments into the heavily-"greentaped" design. Each segment was carefully installed and tack welded and checked to make sure that it was perfect. The green tape works pretty well, but it's nowhere near as accurate as a good tack-weld, and the joint fitments that USED to be good enough for mock-up need to get a LOT tighter in the finished product.... so you can't just cut up a bunch of bends ahead of time. Each one gets cut and fiddled-with until it's just right.

About mid-day.... Charlie decided to come out and "help" me for a little while. :)

IMG_7518.jpg



Clearly, exhaust primary #1 is NOT a very interesting road and needs more attention.

Slowly, but surely the green taped jointed made way for tack-welded ones... and it was time to drop in the final segment to complete the #3 primary tube:

IMG_7522.jpg



The test fitting went great, and I was able to install this finalized design onto the truck without too much drama.... obviously the strut and steering shaft were removed, but otherwise it was a pretty straightforward bolt-in deal. I ended up pulling about 1" of height out of the #5 tube since it had plenty of overall length, and the extra height was just making it harder to fit under the engine cradle bars anyway...

I've still got two complete U-bends left, so I will use those to come up with a new revision of the #1 primary tube. I just didn't like the "look" of it, even though it has a good overall length and good clearances.

IMG_7524.jpg




Hopefully, I can get that dialed-in tonight and start wrapping this header project up for good. :waytogo:


-G
 
I came up with a nicer looking routing for the #1 primary tube last night....

image_3.jpeg



The only problem is that there are only two 180* bends left, and that design needs a total of 400*-worth of bends... :doah:

I will figure something out.


-G
 
When that rig is finished.... Well just think of all the money you'll be able to spend on a good therapist.
Cause brother, I gotta tell you, that's just next level sick right there!:bow::pimp:
 
chevyfumes said:
When that rig is finished.... Well just think of all the money you'll be able to spend on a good therapist.
Cause brother, I gotta tell you, that's just next level sick right there!:bow::pimp:
Click to expand...

Thanks!

There is something very aesthetically satisfying about the new layout....each of those primaries gets progressively taller, and just a tad narrower (in the side view) than the previous one.... sort of like sinusoidal waveforms. Cylinder #1 is a low-frequency, low-amplitude....#3 is medium-frequency, higher amplitude, and #5 is the mack-daddy high-frequency, high-amplitude king. :D


-G
 
Greg72 said:
Thanks!

There is something very aesthetically satisfying about the new layout....each of those primaries gets progressively taller, and just a tad narrower (in the side view) than the previous one.... sort of like sinusoidal waveforms. Cylinder #1 is a low-frequency, low-amplitude....#3 is medium-frequency, higher amplitude, and #5 is the mack-daddy high-frequency, high-amplitude king. :D


-G
Click to expand...
I agree, I love it! Excellent work.
 
Stomis said:
Wo. 7 isnt all rebel without a cause on the bad side of the steering shaft anymore.

It does look much better.
Click to expand...

Yeah, it's a shame I couldn't get #5 to stay on the inside of the steering shaft like the rest of them, but ultimately it doesn't matter because the headers wouldn't have enough room to come out with the steering shaft in place anyway...

I'm pleased with how easily I can drop this assembly into position to bolt it up, considering how crazy the tube routing is.... And I can still reach all the spark plugs and flange bolts!!! :waytogo:

Time to start thinking about the NEXT project to get this motor running..... :thinking:


-G
 
......And for your viewing pleasure.

THE FINAL DRIVER'S SIDE HEADER!!! :waytogo:


IMG_7551.jpg


IMG_7563.jpg



Some interesting final totals for the header build (DS & PS combined):

Total Number of Individual Tubing Segments: 75
Total Number of Bend Degrees: 3517
Total Number of 180* U-Bends Needed: 20
Total Number of Man-Hours: 100+


With the exception of a few small tweaks, the header project is basically DONE. Obviously, there is still a lot of finish TIG-welding to do but that's not really much of a concern. The most important challenge was building headers that would actually FIT in the available space and not hit the tires / struts or body and would still allow sparkplug access and could be removed without pulling the engine first! :D


I learned a lot, and it has been a fun project. Time to move along to the next initiative that gets this truck running.... :thinking:


-G
 
Greg72 said:
......And for your viewing pleasure.

THE FINAL DRIVER'S SIDE HEADER!!! :waytogo:


IMG_7551.jpg


IMG_7563.jpg



Some interesting final totals for the header build (DS & PS combined):

Total Number of Individual Tubing Segments: 75
Total Number of Bend Degrees: 3517
Total Number of 180* U-Bends Needed: 20
Total Number of Man-Hours: 100+


With the exception of a few small tweaks, the header project is basically DONE. Obviously, there is still a lot of finish TIG-welding to do but that's not really much of a concern. The most important challenge was building headers that would actually FIT in the available space and not hit the tires / struts or body and would still allow sparkplug access and could be removed without pulling the engine first! :D


I learned a lot, and it has been a fun project. Time to move along to the next initiative that gets this truck running.... :thinking:


-G
Click to expand...
So 5000$ in labor then to build a set for mine
Want me to haul it up for the winter? I could use the extra space in my shop anyway!
And did you say something about sinus problems now?
Nicely done Greg!
 
76zimmer said:
So 5000$ in labor then to build a set for mine
Want me to haul it up for the winter? I could use the extra space in my shop anyway!
And did you say something about sinus problems now?
Nicely done Greg!
Click to expand...


Zim,

Yeah, these $10,000 Headers will go nicely with my $10,000 Crossmember that I built last year!!! :haha:

It's all a bit of an exaggeration of course, because it always takes a TON of time to learn a new skill and to go through the learning curve where you waste a lot of time and do a lot of head-scratching. After it's all over you've got some cool new skills, and a pocketful of cool shortcuts and techniques that you can use in the future. :waytogo:

At this point, building a set of conventional "inside the framerails" type headers would be a total cakewalk. The only thing I'd do differently is I'd start with tighter bends.... the 3" CLRs that I used for this one wouldn't turn quickly enough to hug the block the way they'd need to for a conventional header build.


-G
 
You must log in or register to reply here.

Latest Posts

Top Bottom