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Header flanges

From 1981 Ford LTD “TractionLTD”, documented by police351.

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1981 Ford LTD - One piece of 1/2" x 2 1/2" flat stock long enough for two new header flanges. 1981 Ford LTD - Fel-Pro 1415 exhaust gasket on top of the stock. I'll be cutting the ports to match the gasket but drilling the wider World Products 3" bol… 1981 Ford LTD - Gasket taped down with the center line of the ports aligned with the center line of the flat stock. Just have to trace the ports. 1981 Ford LTD - Port outlines squared and scribed. 1981 Ford LTD - Taped the gasket back down to the port outlines and punched the corners. That's a piece of 1/2" tube with a transfer punch in the center. T… 1981 Ford LTD - I drilled a 1/8" pilot hole first with a step bit. Then finished it with a 1/8" twist bit. Next I ran a 3/8" bit down the pilot hole and us… 1981 Ford LTD - After all the holes were drilled I scored the lines with a cut-off wheel on my angle grinder. Then I finished the scored areas with a body… 1981 Ford LTD - Once all the holes were roughed out I ground the sides smooth, straight, and square with a tungsten carbide burr in my die grinder. I use a… 1981 Ford LTD - Gasket on top, finished ports in the middle. The cardboard on the bottom has the port layout from my head on it. I held it to the head with… 1981 Ford LTD - I used the cardboard to mark and drill the outermost bolt holes. Then I made relief cuts along the bottom to clear the head bolts and spark… 1981 Ford LTD - After I had clearance for the bolts and boots and got the plate sitting flush with the head, I needed to transfer the bolt holes from the h… 1981 Ford LTD - Finished flange with all the bolt holes drilled, spark plug boots and header bolts cleared, and ports done. Total cost in materials, $10. T… 1981 Ford LTD - Cutting the old header flanges off the headers. The weld penetration wasn't consistent so the surface wasn't very flat. It took a bit of gr… 1981 Ford LTD - Here the flanges have been cut off and a couple have been squared to match the flanges. I welded four 1/2" steel rods to fill the holes in… 1981 Ford LTD - All the tubes have been squared and hammered back into plane and alignment. It matches the flange sitting on it. 1981 Ford LTD - The tubes tacked to the flange. 1981 Ford LTD - I drilled and tapped a 1"x3"x24" piece of cold rolled steel to bolt the flange to while welding. It really worked. The flange was about 1/8… 1981 Ford LTD - Both headers welded to their flanges and the ports ground smooth. I still need to grind the flanges perfectly smooth and maybe grind down t…