NITTY GRITTY

Now, after all of that prep work, the actual construction can begin. This particular set of headers utilizes Burns LLC 304 stainless bends, slip-jointed four-into-one collectors, and V-band flanges imported from California. With the plastic header block dimensions applied, the stainless tubing is cut and prepared. Stainlesssteel requires more preparation time, because any gaps will pull the material, causing it to move a lot more when being welded. Even a 1mm gap can cause up to 10–15mm of movement over a 27inch long runner. All joins must also be cleaned of any contaminants, such as grease, cutting fluid, and cutting disc debris. Any of these will affect the weld, and, if not cleaned off, may be pulled into the molten pool when welding. Any contaminants pulled in can affect the strength of the weld. The TIG welding is done with full penetration and back purging with argon gas, which is done for extra weld strength. Both ends of the tube section being welded are plugged with aluminium foil, and the tube is filled with argon. As argon is heavier than atmospheric air, it sinks into the pipe, forcing air to the top and out the hole, and filling the inside of the tube with argon. This allows full weld penetration with argon shielding on both sides, protecting the weld from atmospheric contamination. The first stage of header construction involves tack-welding the tube section together, enabling easy revisions to be made to positioning if required. The pipe is then mocked up to ensure it clears everything it is supposed to, including a lock-to-lock steering check. It is then removed for the next section to be tacked on, and another physical check done. This is repeated as many times as necessary, until the individual header pipe is completed, and all joins can be welded. Once welded, the weld is visually inspected for any imperfections. The above process is then repeated for the next individual primary pipe, and continues until all four pipes are completed.