2Loose Willy's Gasser Project, .....................

Fabbing Up A Set Of Fenderwell Headers........

Decided to try to save a little time on fabbing up the fenderwell headers by buying a set of BBC headers for the '55 and cutting and adapting them to the Olds motor. They are Doug's Headers and are nicely made.

So I whacked off the mounting plates and have ordered a set of exhaust header plates for the Olds exhaust pattern from Jegs.

The Edelbrock heads on this motor have been ported by my buddy John, who is a retired top fuel thechie for Alan Johnson (Alanabi Racing), and he did a nice job on them! The header flanges I have for the Olds motor need to be port matched to the exhaust ports, as these ports were raised about 3/16" during the porting process. I can't get a good photo of the exact amount of port-to-flange mismatch because the motor is in the frame for the fenderwell header build, but these pix show the adjustment that was done.

As the flange openings are quite a bit larger vertically than the exhaust port, I decided to just raise the flange on the head and move the bolt holes. There is a centered bolt hole on the head just above the two center exhaust ports, so I started by hand filing that center flange bolt hole to raise the flange the required amount, about 3/16", to get alignment of the top of the four flange exhaust holes to the top of the exhaust ports.

Here's the flange in the "stock" location before raising it up, you can see how much that bolt hole was filed on the bottom, that's how much it has to be raised:

I put a bolt in that center hole and slowly filed that flange opening, rechecking it often, slowly raising the location of the flange until I got a perfect alignment of the flange with the top of the exhaust ports:

Here's a closeup of the flange in the "stock" position, but with the filing of that center bolt hole in the flange completed:

Here's the flange in the raised position:

Now I need to weld up the rest of the bolt holes and redrill them for the new, raised location.

It's a small thing, but that flange hanging down 3/16" into the exhaust gas flow path will disrupt the performance of the motor by quite a bit at full throttle, and after spending all that effort to port these heads, these flanges needed to be port matched to the new heads!

That open step at the bottom of the exhaust port where the flange is larger than the port should have no effect on the exhaust flow, and in fact may have an anti-reversion effect (I'm betting on it!), which is a good thing!

Next I made up a die to help form the square ends on the 2-1/4" tubing for the header plate stubs. 2" was too small for this, so I'm using this 2-1/4" for the header plate stubs, but the BBC headers I'm matching to this are 2", so some transition work will also be required to match that up:

Pound the die into the tubing a little at a time, hammering the sides of the tubing down square a little at a time as the die is hammered into the tubing, until it is nice and squared off:

Remove the die and cut to desired length:

Tak weld the stub to the header plate, one corner at a time, some hammering was required here to get a perfect fit.....

Once the fit was achieved, I welded it up....

Then I fitted the headers to the stub on the motor. I would rather have had a piece of curved tube for that stub, but I couldn't find any 2-1/4" 90 or U bends locally, and didn't want to wait until pieces could be ordered, so decided to just go ahead with the straight pieces. It will perform just fine, but I think it would look better if I had put a curved piece in there between the plate and the header tube.

The fit along the firewall and inside of the fender is good, so I added connections to the other ports.....

Cylinder #2 needed to loop up and over the shock mount, it took five pieces before I got it the way I wanted!......

Later I'll add a "Y" and some race ready elec. cutouts, and a street exhaust system off of the "Y"....

Got the driver's side finished too....

Had to make sure the #7 cylinder cleared the clutch pedal assembly when it was depressed all the way.... And the steering linkage....

Latest Update (3/15/10):

I added the Y's and the Race Ready elec. cutouts to both sides. Still need to add a muffler system, I'm thinking Smitty glasspaks, hope they won't be TOO loud, I do live in a quiet neighborhood, they sorta put up with me, but wait till they see this rig! I've also used the Dynomax Ultraflow mufflers, they are straight through glasspaks, and seem to hold up well. And not too loud until you get on it!

This first shot shows the layout of the header system for the driver's side, tacked together and ready for welding. The next two show the welded up passenger's side setup, ready for smoothing of the welds and painting. I will add hangers on both sides to take the strain off of the heads/flanges.....

I think fenderwell headers really add to that old gasser look!!! I'm undecided on painting them flat white or flat black. White would look good, but would be difficult to keep clean! I need a fresh pic here, but will wait 'till they are final painted and hung back in there....

I did pretty much the same thing on the other side. That required additional clarance for cylinder #7 for the steering linkage and the clutch linkage, so I got some more 2" 180's to cut up for that!

They came out pretty nice, and fit the car the same as the other side did.

On the driver's side, I never did like the way the #5 cylinder tube came off the flange. As these were BBC fenderwell headers for a tri-five that I adapted to my Olds setup, I just fitted it to the Olds flange, but never liked that nasty bend in there....

So I whacked that out and fitted in another setup. Here it is tacked in place, now I need to weld it up solid, then I can "polish and paint" the headers.....

More later......

Here's some links to more pix:

Dog Dish Hubcaps? Air Filter Rain Covers? Looks Good To Me........

Setting Up The Rear Axle and Suspension page 2

Setting Up The Rear Axle and Suspension page 1

Cutting A Hole In The Hood, and Setting The Fenders....

Installing The Radiator

Setting Up The Tilt Front End

Setting Up The Steering and Suspension 2

Setting Up The Steering and Suspension

Starting To Fit Some Parts Here and There....

Setting Up The Front Axle 2

Setting Up The Front Axle 1

Narrowing The Front Axle

Found This Ford F100 Front Axle

Assembling The Blower Motor

Reworking an Olds 425 to take a 6-71 huffin on it.

Trial fit for the 6-71, a Don Hampton special.

Pulled apart a '67 Olds 400 motor for spare parts.....

Did Some Porting Work on some Edelbrock Olds Heads

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