bottom side of the header





the inside of the header (nearest to block)



how would you guys go about in repairing this header.
it's a moogen so i'd like to save it, if at all possible. thanks

 

You could, cut out the damaged area.. then just weld new pieces in...

Its not easy to repair..

 

you'll need to seal both sides of the header. The o2 bungs, head flange, and the outlet. with a gasket and a steel plate. MAKE SURE it doesnt leak. weld on an air fitting for your air compressor.

Pressurize the inside of the header.... to 60-80 psi

now take a a rosebud and SLOWLY and CAREFULLY heat it. The pressure on the inside will push the crushed parts out.

 

we do it with motorcycle exhausts all the time just like erik said, except we don't use compressed air.

 

What do you use, nitrogen???
That's a neat trick, I did it the hard way, cutting and welding.
I see this all the time on the domestics...
Thanks, learned something very useful today!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 9bells &raquo;</TD></TR><TR><TD CLASS="quote">
Thanks, learned something very useful today! </TD></TR></TABLE>

x2

 

weld a bolt to the dents and heat up the area that is dented and pull it out and cut the bolts off and grind smooth... works very well...

 

Couldn't you pull a ball through it while heating it? It will have to be a ltiile smaller than the opening to get it through. Isn't that what they do for mandrel bends?

 

when they make mandrel bends they usually use a spring lookin thing on the inside when they bend it. It doesnt allow the tube to crush

 

or they pack the tube with styrofoam or sand

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by NUISANCE &raquo;</TD></TR><TR><TD CLASS="quote">Couldn't you pull a ball through it while heating it? It will have to be a ltiile smaller than the opening to get it through. Isn't that what they do for mandrel bends?</TD></TR></TABLE>

what the hell??? what happens when the ball gets stuck???

 

cut the tube and pull it out

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Eric@HorsepowerFreaks &raquo;</TD></TR><TR><TD CLASS="quote">you'll need to seal both sides of the header. The o2 bungs, head flange, and the outlet. with a gasket and a steel plate. MAKE SURE it doesnt leak. weld on an air fitting for your air compressor.

Pressurize the inside of the header.... to 60-80 psi

now take a a rosebud and SLOWLY and CAREFULLY heat it. The pressure on the inside will push the crushed parts out. </TD></TR></TABLE>

Great Stuff

 

Pull it back out the other way or hit it with compressed air. The ball thing was just a thought.

 

they do it when making mandrel bent copper tubings for instruments. You bend the metal with a regular bender then they shove metal ***** through the tubing. THey use a ball thats the size of the inside diameter of the tubing then use a few smaller ones to push the big one all the way through. The big thing that allows this to work correctly, the tubing is put in a metal form that holds the tubing perfectly. When the ball travels through, it has to follow the path and only allows the metal to press out on the sections where it has bent in...

 

wow. so this process definitely recquires more knowledge of fabrication than i have. how much would such a thing cost?

 

bondo it, and repaint FTFW!!! haha

 

the ball thing?

You gotta have the metal backing to do it... they use a block of steel/aluminium, cut the thing in half and machine out 1/2 the bend on each side... Then they put the tube in the block of metal put it in a vice so it cant move..then they use the metal ***** to expand the pipe. You cant really do it at home as a repair..its more of a manufacturing thing.

 

you are probably better off using it as scrap. lol.
a new header is worth less than that thing would be to repair.


what kind of header is it that makes you want to try to repair it rather than cutting it up in to tiny little bits and throwing them at your friends and enemies?

 

yeah i just wanted to see if it's worth saving. if not, i'll probably just sell it on ebay for however much i can get out of it. not too worried about it.

 

Cut off the engine flange and sell it. You could also sell the collector part.

 

DC sports collecors are not worth anything.

IMHO, just get another header. Not worth the time or money to fix it.

 

but it's not a DC header. it's a Mugen header

 

could try a stud welder and slide hammer if you have access to one. I dont know if it will work, but it's worth a shot.

 

Heat and Use compressed air to pull it back together... I've seen it work on far too many headers, we saved an old school T1R like that.