police351 > 1981 Ford LTD > open folder Header flanges

One piece of 1/2" x 2 1/2" flat stock long enough for two new header flanges.
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481 hits | 91.55 KB | Posted: 2/20/10
One piece of 1/2" x 2 1/2" flat stock long enough for two new header flanges.
Fel-Pro 1415 exhaust gasket on top of the stock. I'll be cutting the ports to match the gasket but d...
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376 hits | 88.34 KB | Posted: 2/20/10
Fel-Pro 1415 exhaust gasket on top of the stock. I'll be cutting the ports to match the gasket but d...
Gasket taped down with the center line of the ports aligned with the center line of the flat stock. ...
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400 hits | 80.61 KB | Posted: 2/20/10
Gasket taped down with the center line of the ports aligned with the center line of the flat stock. ...
Port outlines squared and scribed.
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407 hits | 92.5 KB | Posted: 2/20/10
Port outlines squared and scribed.
Taped the gasket back down to the port outlines and punched the corners. That's a piece of 1/2" tube...
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397 hits | 79.91 KB | Posted: 2/20/10
Taped the gasket back down to the port outlines and punched the corners. That's a piece of 1/2" tube...
I drilled a 1/8" pilot hole first with a step bit. Then finished it with a 1/8" twist bit. Next I ra...
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344 hits | 104.25 KB | Posted: 2/20/10
I drilled a 1/8" pilot hole first with a step bit. Then finished it with a 1/8" twist bit. Next I ra...
After all the holes were drilled I scored the lines with a cut-off wheel on my angle grinder. Then I...
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392 hits | 88.63 KB | Posted: 2/20/10
After all the holes were drilled I scored the lines with a cut-off wheel on my angle grinder. Then I...
Once all the holes were roughed out I ground the sides smooth, straight, and square with a tungsten ...
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384 hits | 92.2 KB | Posted: 2/20/10
Once all the holes were roughed out I ground the sides smooth, straight, and square with a tungsten ...
Gasket on top, finished ports in the middle. The cardboard on the bottom has the port layout from my...
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440 hits | 91.11 KB | Posted: 2/20/10
Gasket on top, finished ports in the middle. The cardboard on the bottom has the port layout from my...
I used the cardboard to mark and drill the outermost bolt holes. Then I made relief cuts along the b...
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456 hits | 90.3 KB | Posted: 2/20/10
I used the cardboard to mark and drill the outermost bolt holes. Then I made relief cuts along the b...
After I had clearance for the bolts and boots and got the plate sitting flush with the head, I neede...
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394 hits | 92.64 KB | Posted: 2/20/10
After I had clearance for the bolts and boots and got the plate sitting flush with the head, I neede...
Finished flange with all the bolt holes drilled, spark plug boots and header bolts cleared, and port...
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572 hits | 87.62 KB | Posted: 2/20/10
Finished flange with all the bolt holes drilled, spark plug boots and header bolts cleared, and port...
Cutting the old header flanges off the headers. The weld penetration wasn't consistent so the surfac...
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490 hits | 84.1 KB | Posted: 3/14/10
Cutting the old header flanges off the headers. The weld penetration wasn't consistent so the surfac...
Here the flanges have been cut off and a couple have been squared to match the flanges. I welded fou...
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554 hits | 86.59 KB | Posted: 3/14/10
Here the flanges have been cut off and a couple have been squared to match the flanges. I welded fou...
All the tubes have been squared and hammered back into plane and alignment. It matches the flange si...
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476 hits | 91.62 KB | Posted: 3/14/10
All the tubes have been squared and hammered back into plane and alignment. It matches the flange si...
The tubes tacked to the flange.
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478 hits | 67.83 KB | Posted: 3/14/10
The tubes tacked to the flange.
I drilled and tapped a 1"x3"x24" piece of cold rolled steel to bolt the flange to while welding. It ...
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439 hits | 68.15 KB | Posted: 3/14/10
I drilled and tapped a 1"x3"x24" piece of cold rolled steel to bolt the flange to while welding. It ...
Both headers welded to their flanges and the ports ground smooth. I still need to grind the flanges ...
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494 hits | 67.93 KB | Posted: 3/14/10
Both headers welded to their flanges and the ports ground smooth. I still need to grind the flanges ...