Daihatsu Exhaust Header

[oilburner]

Another milestone. Fabrication of the exhaust header was a job I dreaded. It took two friggin weeks to make. Each elbow was fabricated from 5 separate wedge shaped pieces of tubing welded together, plus 2 wedges for the 45 degree at the bottom of the front cylinder elbow - 17 in all. Lots of welding and die grinding.

In response to your anticipated question, yes - 4 bolts *are* required for the flanges. There isn't room between the bolt holes and the exhaust port in the cylinder head for the tubing, to permit the use of a conventional style 2 bolt flange. I made up adapter flanges retained with countersunk sockethead bolts.

Next, a Y connector will be welded to the outlet, for left/right exhaust pipes and mufflers.

The grainy appearance and lines are from the crappy flat black paint that I sprayed on prior to taking the pic. The header will be attached using studs and the OEM mechanical lock nuts. A stainless heat shield will be installed, although it won't be absolutely critical as the header tucks neatly against the engine several inches away from the riders leg.



Gettin there,

Avery

[oldbmw]

That is a great piece of fabrication. Making those lobster or snailbacks takes a lot of time to get right, and you cant always start from the easiest point because then you cant clean up the welds inside very easily.

[SNOOT]

Look at it this way I don't think you will have any exhaust leaks at the head with four bolts on each header pipe...

Nice work looks great..