mjims

Kevin

this is Excellent advise, I have just done this very modification to mine.

My Flange was only welded by the Factory on the inside and as I ground it down I was worried about it cracking or failing.

I would like to recommend that people apply an additional weld on the outside of the flange to help strengthen and brace it.

Good post, I think this type of advise is priceless

Jean

Hal, thanks. These are Cargraphic racing 19", 9Fr X11Rr If I remember correctly. They look too shiny on the pic, they are not like that.

Jean

Kevin

Jim;

I would caution people not to weld the header/exchanger. As these units get some miles on them, rewelding the stainless can promote cracking. As usual the actual weld won't crack, but the adjacent line around the weld will posibly crack. So again we want to just smooth out the weld inside of the flange like I did. As you smooth it, you will feel the ridge from the factory weld, leave it, just make it smooth, leave the low spots. If you look closely this weld is fusion welded. This means that it is heavily heated with a tig welder, with little to no welding rod, the metal are fused together thus creating very good penitration in the weld...

mjims

Yes I know,

The original weld on my flange was showing some small hairline cracks, hence the wanting to strengthing it.

I gave mine to a local Welding specialist just incase I cocked it up!

My welding resembles Bird poo !

I should have remembered to state that Stainless Welding is a highly specialised skill.

Kevin

I like that "incase I cocked it up"

sharkster

Darn those 993 TT headers are different I'm just glad Kevin modified mine into these: [img]http://www.mangogrits.com/akula/upload/header.JPG[img]

Notice the porting...

Carrera GT

Kevin,

Thanks for taking the time to post this thread.

I'm going to take your advice on my factory headers.

"While I'm in there" ...

Do you do all your work on KKK? Is there a "cheap" source for appropriate turbos to have you work your magic?

Cheers,

Kevin

GT;

You can find them on ebay or classifieds, race shops, dealers.. or just put the word out.. I am always looking for cores!!! I jsut can't get enough of them..

I need to add that, after the porting, one must take extra care in the cleanup of the exchangers. Take them to a car wash, use a garden hose, we want to make sure that all of the metal is out of the hidden joints.. After this, one needs to find there way into the wifes kitchen, make sure that you give her a $100-??? to get her out of the house. Put two cups pf cascade in the dishwasher and let her rip... I assume that you put the units in with the ports facing the jets... You'll be amazed at how clean they come out... One customer got so carried away that he polished the entire outside of the stainless to match his porting!!!

Good luck

Acropora

One year later, I debating doing this mod... Todd Knighton said he'd guess it was worth 3%.

Kevin

Why debate it. just do it.. Get your hands dirty, grab the grinder, go buy a Dremel and have some fun..

Jean

Brad, at what time did you ask Todd that question? he must have been in a good mood The fun factor is worth much more than that anyway.

Acropora

Jean, at the end of the day... maybe it was Miller time...
Good point Kevin. Well, Jeff Jones at Automotive Techniques in Detroit is putting in the turbos and unfortunately he doesn't work for free, heh. If I was doing it, no doubt some beer and fun with the Dremel would be had.

Rickard 993 Turbo

The pictures is not working..

Kevin

I'll have to find my original pictures.. Maybe John D has them??

jmayzurk

Here are pictures of my headers, which I just pulled off while Kevin is rebuilding my turbos.

The collector in the right header (cyl 4-6) could stand some improvement:



...but the left one doesn't have the same problem:



I'll post pictures again after I'm doing cleaning them up.

-Jeff