Any interest in header flanges?
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Thread: Any interest in header flanges?

  1. #1
    Project 1450 supporter... Site Supporter RallyBob's Avatar
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    Header flange interest?

    I am having some water-jet cutting done this month. Included will be some Opel CIH header flanges, made from .375" thick A-36 steel plate. I will be welding half-washers at the appropriate places so the thickness matches the intake flange. Is anyone interested in buying these so you can build your own header? I won't be having a lot of them made, but based on my initial quantity the selling price would be about $43-45 including the TIG-welded washers. My cost will be $36 not including my labor to weld the washers in place. Not a money-making proposition, but it allows me to have enough made to get the overhead down a bit. This is a brand-new design BTW, not a copy of an old Pacesetter, etc., so it is accurate and clean. Same design as the one on my turbo header.

    Bob
    Last edited by RallyBob; 07-07-2004 at 02:15 PM. Reason: thread title change

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    Southern Red Neck BQS4's Avatar
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    Flanges

    How soon would you have to have the money?
    "Yes, I do have a rifle rack in my Sportwagon"

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    Project 1450 supporter... Site Supporter RallyBob's Avatar
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    I will be paying for them myself. No money up front needed. Expect 2-4 week turnaround.

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    Southern Red Neck BQS4's Avatar
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    Flanges

    Bob;
    Then put me down for one. Let me know when I need to send the money. I'm in no hurry, but, it would be nice to have a good, (read-correct), header flange.
    Gene
    "Yes, I do have a rifle rack in my Sportwagon"

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    Member cherokee's Avatar
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    Put me down for one. Drop me a note when you need the $$$.

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    I'm in for one.

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    Count me in as well.




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    tomking
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    count me in for one Bob. Thanks.
    TMK

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    Count me in.
    Trent

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    Opeler Site Supporter wayne70gt's Avatar
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    I may be interested for future use. Are there any threads describing how to complete the header? How difficult a job is it? Estimated cost to have done professionally?

    Wayne

  13. #11
    Project 1450 supporter... Site Supporter RallyBob's Avatar
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    Quote Originally Posted by wayne70gt
    I may be interested for future use. Are there any threads describing how to complete the header? How difficult a job is it? Estimated cost to have done professionally?

    Wayne
    No threads as of yet....

    I dabbled a bit into the fabrication process of building a turbo header for another thread. The process definitely entails some fabrication skills, but I would not consider it to be horrendously difficult (unless you're impatient). On a scale of 1-10 I'd say it's a 5 or 6. A rollcage is substantially more difficult in my opinion.

    Going into the project, you must first have a good idea about the design of the header (tubing diameter, primary runner lengths). Next, and to me most importantly, you must be able to visualize the tube locations under the hood. Some people can just look at it, and start building a header. I'm not one of those people. I prefer to use wire (1/16" gas or TIG welding wire works great), and cut 4 pieces to the same length as the primary tubes. I then bend the wire into shape and using tape will secure it into approximate position, making sure all 4 'tubes' do not interfere with each other, nor with the intake manifold, the block, the engine mount, etc. And once this is done, I remove just one piece of wire, and use that as a visual aid to start cutting and tack-welding tubes together, constantly test-fitting as I go along. When one tube is completely done, pull another piece of wire, and start on the next tube....etcetera, etcetera.

    Estimated time to construct? This depends on your skill level to 'eyeball' where each tube goes, and your skill as a welder. My first header took me 10-11 hours. The next one took me 8 hours. The next one took me 6.5 hours. But they all pretty much take me 8 or 9 hours now, probably because I'm more finicky and prefer not to rush things along. I hate doing things twice!

    The turbo header I refered to earlier probably took me 12-14 hours. But I also ground down all the welds, and polished it smooth to make it 'pretty'. That takes time.

    If you had to pay a professional to build it, he'll probably charge you for a day to a day-and-half of labor. If the hourly rate is $50, then it's a $400-$600 header, not including parts. That seems to be the general range for custom headers from what I've seen.

    You should be able to build it yourself for around $100-$120 worth of parts, plus your time. And that's assuming you use a nice quality custom collector, which will blow one of those mass-produced cheapie collectors into the weeds in terms of efficiency and quality!

    HTH,
    Bob

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    Super Moderator Ooooner's Avatar
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    Count me in!

    Bob,
    Count me in as well. Just let me know when it is ready to ship and I will send you the $$$$... Thanks!
    Roy Bell
    1973 Opel GT
    Concord, North Carolina
    Carolina Opel Club

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    Have Opel, Will Travel oldopelguy's Avatar
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    me two

    Count me in for 2, Bob, just in case. Any chance this is the same guy making them that made the intake flanges, and a couple more of them could be made too?

    As to the header, one option to maybe consider, if someone has access to some sort of speed shop, might be to take a look at right side headers for Chevy or Chrysler v-8's. The small block Chevy pipe spacing is close enough to probably work, and there might already be a header out there somewhere that'll drop right in with the new flange welded on. It would take an agreeable vender and some time on the part of an Opel owner test fitting, but if someone lived near Summit or Jegs and had some time to kill....
    Lots of Opels, for a long time.

  16. #14
    Project 1450 supporter... Site Supporter RallyBob's Avatar
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    Quote Originally Posted by oldopelguy
    Count me in for 2, Bob, just in case. Any chance this is the same guy making them that made the intake flanges, and a couple more of them could be made too?

    As to the header, one option to maybe consider, if someone has access to some sort of speed shop, might be to take a look at right side headers for Chevy or Chrysler v-8's. The small block Chevy pipe spacing is close enough to probably work, and there might already be a header out there somewhere that'll drop right in with the new flange welded on. It would take an agreeable vender and some time on the part of an Opel owner test fitting, but if someone lived near Summit or Jegs and had some time to kill....
    Stephen, I still have some of those intake flanges if you're interested. Found them all yesterday in fact. Not the same vendor as the new header flanges however....
    1.9 or 2.2 head? Let me know.

    I've known of three people that adapted a small block header to an Opel. All of them said they would never do it again, after they cut and fit it and made the flange work they had as much time into it as a custom header, FWIW...
    The other problem is finding an equal-length SBC header with 34 to 38" long primaries that are only 1.5" in diameter. Most of them are 1 5/8" or 1 3/4" and much shorter, which is fine if you are racing your Opel and only need 6000-9000 power...

    Bob

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    Bob,

    I'll take 2 exhaust and 2 1.9 intake flanges.

    -Travis

  18. #16
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    Bob, I'll Take one also if you're still taking orders.

    Thanks,
    ~ Tom

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    Ok intake flanges, I'd like two of those for a 1.9 if at all possible.




  20. #18
    Project 1450 supporter... Site Supporter RallyBob's Avatar
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    Actually the intake flanges are from my personal 'stash', and not for sale. I'm just returning a favor to Oldopelguy, he got me a Sprint intake manifold.

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    Cunning Linguist Site Supporter tekenaar's Avatar
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    ArrowExhaust flanges

    Bears repeating . . . you do such nice work, Bob. Nice to know there's someone else out there just as anal about fabricating things ONCE!

    Sign me up for one of your CORRECT exhaust flanges.


    1960: '61 Rekord PII 1.7 3S 3.9 '69 Kadett LS 'sprint' 1.9 3A 3.18
    1970: '70 GT 1.9 4S 3.44 '72 GT 2.2SSD 5S 3.44 '72 GT 2.4FI 5S 3.44P
    1970: '73 GT 1.9FI 4S 3.44 '75 1900 1.9FI 4S 3.44
    1980: '85 Bitter SC 3.9FI 5S 3.44P
    2000: '09 Solstice GXP Coupe 2.0 SIDI VVT "Stage 2" Turbo 5S 3.73P


    "De inimico non tantum loquaris male, sed cogites."

  22. #20
    Opeler
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    Bob I like to get one of the header flanges also

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