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Discussion Starter #1 (Edited)
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
 

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Discussion Starter #3
I will be paying for them myself. No money up front needed. Expect 2-4 week turnaround.
 

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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
 

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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
 

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Discussion Starter #11
wayne70gt said:
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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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!
 

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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....
 

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Discussion Starter #14
oldopelguy said:
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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Discussion Starter #18
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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Exhaust 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.
 
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