Northy
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| posted on 20/12/03 at 07:20 PM |
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Bending exhaust pipe?
Right, I've got some 40mm thin wall (1.5mm) mild steel exhaust pipe to make my front header pipes from, how do I bend it without deforming
it?
And, does anyone have any pictures of there front header pipes? Does it matter which cylinder goes where in the 4 to 1 collector? Do you just try to
get them all the same length?
Cheers
Graham
Website under construction. Help greatfully received as I don't really know what I'm doing! 
"If a man says something in the woods and there are no women there, is he still wrong?"
Built 2L 8 Valve Vx Powered Avon
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Jon Ison
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| posted on 20/12/03 at 07:43 PM |
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without "formers" think u will struggle, heard of people filling pipe with sand B4 bending, never tried it myself, pr-bent bends maybe yr
best option,
i go to local exhaust centers with hacksaw, they usually let you loose cutting the best bits out wrotten systems they have taken off, bends
ect..........
if yr going 4-1 then in an ideal world all the pipes should be exactly the same lengh, this lengh though for perfection can only be found on a dyno,
measure an after market system, they should'nt b 2 far off the mark.....
all IMO only btw.
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MikeR
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| posted on 21/12/03 at 01:43 AM |
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The length really depends on what you want the car to do! 4-1 is better for top end power, 4-2-1 is better for mid range. If you put all the
collectors at different lenghts then you'll get power spread through the power band......
If ultimate power is your goal then measure a system, read the books and do the maths. If you just want to drive on the road i'd be tempted to
just make something that fits.
If you're trying the sand bending make sure you use kiln dried sand - normal sand is too moist and risks an explosion. Do a search on here, its
bound to have been covered.
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200mph
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| posted on 21/12/03 at 02:10 AM |
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took the words right out of my mouth.
Four stroke performance tuning by A. Graham Bell covers primary lengths etc in good detail, as well as diameters of the various pipes for optimal
torque/power etc at different rev ranges.
very worth reading IMO
Mark
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PeterGT4
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| posted on 21/12/03 at 05:55 AM |
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I've found that bending tubing using sand & heat (the ends of the tube securely plugged to contain sand) still puts kinks (slight ones mind
you) on the insides of the bend.
For the best/cleanest results, madrel bending is the way to go. You'll need to go to a specialist with the right (expensive) tools to do this.
Worth it though.
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suparuss
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| posted on 21/12/03 at 10:20 AM |
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thse might help if you do the sand bending thing- sorry theyre a bit big, but they need to be so you can read the writing. 
 
Rescued attachment sandp62.jpg
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mangogrooveworkshop
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| posted on 21/12/03 at 10:24 AM |
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why learn to bark when there is plenty dogs to do it for you
Try http://www.powerflow.uk.com/ they can help the company did my Suzuki bike
and my VEE TROUBLEYOU BEETLE and its all custom made4
http://www.northerntooluk.com/product/search.asp?k=pipe+bender&i=&action=search&x=7&y=6
[img]http://[/img]
12-Tonne Hydraulic Pipe Bender
Item No. 14420E
Bends Virtually All Types Of Pipe.6 Cast Iron Shoes For 12.7Mm To 50Mm Diameter Pipe, Top Rollers Adjust For Degree Of Bend, 609Mm L X 546Mm H X 159Mm
D, 1 Year Limited Warranty
For 96 squid cheep as chips
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suparuss
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| posted on 21/12/03 at 10:26 AM |
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part 2-
 
Rescued attachment sandp63.jpg
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suparuss
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| posted on 21/12/03 at 10:27 AM |
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part 3-
 
Rescued attachment sandp64.jpg
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suparuss
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| posted on 21/12/03 at 10:28 AM |
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woohoo, last part-
 
Rescued attachment sandp66.jpg
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suparuss
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| posted on 21/12/03 at 10:33 AM |
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m\ngogroove- those hydraulic pipe benders wont do thin wall stuff, with only having a small former, and 2 mandrels the pressure is concentrated too
much into one area and just buggers up the steel. theyre used for scaffold tube type stuff.
Russ
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Northy
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| posted on 21/12/03 at 11:58 AM |
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Suparuss thats brilliant, thanks.
<Puts on Avid Merrion voice>
I fu**ing love you!
<Puts on Lard voice>
I'm not gay or owt.
Graham
Website under construction. Help greatfully received as I don't really know what I'm doing!
"If a man says something in the woods and there are no women there, is he still wrong?"
Built 2L 8 Valve Vx Powered Avon
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suparuss
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| posted on 22/12/03 at 10:25 AM |
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lol, no probs m8. cant remember where i found it but thought it would come in handy when i came to do me exhaust, then again ill probably take the
lazy route and use jetex pipe sections and weld em together.
Russ.
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locoboy
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| posted on 22/12/03 at 12:17 PM |
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Agreed those hydraulic ram type benders are only for use with heavy duty stuff. it just kinks or creases thin walled stuff.
ATB
Locoboy
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mackie
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| posted on 22/12/03 at 01:05 PM |
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Where can you get these Jetex bits of which you speak? I asked custom chrome about prices for a RV8 header kit and then promply cried. That's a
lot of wonga for what is a few bits of pipe!
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stephen_gusterson
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| posted on 22/12/03 at 03:19 PM |
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it wont look quite as swish, but there is another way.
If you have ever seen the hotdog that used to come with a wimpy international grill, you will know.
Cut the tube in stages / segments around the bend, taking little slices out, squeeze it all together, then weld.
Thats how I did my exhaust system, but its all under the car / bonnet on mine. Might work tho......
atb
steve
[Edited on 22/12/03 by stephen_gusterson]
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suparuss
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| posted on 22/12/03 at 06:11 PM |
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hmm flow might be interupted a bit by all those welds  . can get jetex bits from burton power or demon tweaks
etc should have em.
oh yeah and merlin motorsport do em as well.
Russ.
[Edited on 22/12/03 by suparuss]
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JoelP
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| posted on 22/12/03 at 06:51 PM |
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you're right about the welds affecting the flow, but compared to the original system it is probably missing one silencer/expansion box, plus
maybe using fatter pipes in places, so it wont be too bad IMO!
Beware! Bourettes is binfectious.
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blueshift
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| posted on 23/12/03 at 02:16 AM |
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you could chop lots of little tube wedges and weld them together one by one, grinding / filing smooth the weld inside after each weld with a dremel or
something.
this would, of course, be silly.
perhaps if you were going to go the cut out vees route anyway though, and you cut the back wall close enough that you could hinge it back to clean up
the welds as you went along.. hmm.. something to consider?
but still quite silly.
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stephen_gusterson
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| posted on 23/12/03 at 09:58 AM |
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yes, the flow wouldnt exactly be F1 standard, but if you are running a std road tune engine like my V6 with std contorted manifolds, I dont recon it
would make that much odds!
The sand and bending technique looks easy in the pics, but I bet its a damn site harderin real life when its yer first attempt. And it seems to use a
specialiesd torch.
seeing as (if you are like me) its all gonna be done in a std garage with bum all equipment, making up a bend out of segments may not be as silly as
it sounds.
If you dont want A1 gas flow to the nth degree, a 90 deg bend can be made up of cut segments - about 3 does it.
The very large dia tubes that form the roof of my local shopping centre are done like this. Yes - its not an exhaust, but if you are running - for
example - a std pinto and you want a simple way to make a bend in pipe in a minimal garage - is it gonna make that much BHP difference.......
atb
steve
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Simon
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| posted on 23/12/03 at 12:44 PM |
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Chaps,
Your can get the Jetex bends from....
Jetex
Agree with Mackie - CC Vey expensive. I know equipement exp. but a foot of 1.5" 16swg ERW is about 30p.
Also agree with Steve - I have a load of mandrel bends - some needed radiuses tightening, so I just cut and welded.
Not worried about weld intrusion. When I've got £500 spare, I'll get exhaust made properly.
ATB
Simon
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DaveFJ
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| posted on 23/12/03 at 01:14 PM |
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Recently met up with 'Type 907' and his exhaust manifold is a work of art.....
Image deleted by owner
apparently it is totally smooth on the iside as well!
Dave
Dave
"In Support of Help the Heroes" - Always
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xroger
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| posted on 11/4/04 at 01:54 PM |
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Pipe bending.
The only way to do it your self really is to buy some mandrel bent elbows and matching size tube and cut/weld together.
Such systems ( presuming your ok at welding) would be far better for performance and cost.
The only trouble with the previously mentioned "power flow" systems is that they are made from low quality materials/ bent on a normal
exhaust bender ( which crushes diameter of pipe) and often welded by monkeys!
Adding to that that they are over priced!
Rgds
Roger www.shinybitz.co.uk
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xroger
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| posted on 11/4/04 at 02:04 PM |
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link not working trying again.
Rgds
Roger
http://www.shinybitz.co.uk/
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