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Merge collectors and jigs and cutting techniques

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  • #1

    Merge collectors and jigs and cutting techniques

    I'm making my own 4-2-1 unequal length header for my turbo b6d project. Nobody sells simple prefabd 1.25 sch 10 304l stainless 2-1 merge collectors. So I'm stuck making my own. I went out and bought a double angle miter saw hoping I could just whip out reliable and reproducible merges. My first jig caused alot of blade wander because I was starting the cut on the side of the pipe. This technique was never going to work with double angle cut pipes if i wanted to make 4-1 collectors. It was not accurate enough.
    And then it hit me. This was how to do it
    My mdf wood clamp holds very firm, and I only have clean up towards the bottom of the cut due to depth cutting issues

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  • #2
    That was with the pipes merge start point lined up. Pipes turned out a touch different length but I think it will work fine, just need to trim up the outlet after welding.

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    • #3
      Pretty slick! If your going to be playing a lot with stainless pipe, invest in a powerful belt sander and some quality 60 grit belts. That will make it possible to get perfect joint fitment.
      your also going to want to bevel your weld joints and purge the part with argon.
      Driving for me is neither a right nor a privilege. Driving is my passion, as it was for the people who invented the automobile, the people who paved the first roads and the people who continue to improve the automobile. Please respect this passion.

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      • #4
        Originally posted by Advancedynamix View Post
        Pretty slick! If your going to be playing a lot with stainless pipe, invest in a powerful belt sander and some quality 60 grit belts. That will make it possible to get perfect joint fitment.
        your also going to want to bevel your weld joints and purge the part with argon.
        I have a 12 inch disk/drum sander. It's flat and spins in a circle. Idk for sure what it's called. I think the pad I just put on it today was like 30 grit. It's sharp.

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        Last edited by bhearts; 08-12-2016, 09:51 PM.

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        • #5
          I'd prefer to cut on a bandsaw. I think they provide the best quality cut. But entry prices for something decent are pretty high. I'd like to have a horizontal bandsaw also for exhaust work, but that's not exactly optimal for cutting merge collector angles

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