72 Dart Swinger 3.6L Pentastar +T5
EXHAUST Headers:
I got the Passenger side tack'd and ready for TIG, so i figure a little more comprehensive description of my work.
The 3.6 Pentastar has an odd ball single exhaust port. First task was getting new flanges. The flanges were cut from 3/8 stainless to these dimensions
To get the weird shape formed, I used an old Catalytic Convertor flange cut in half and weld to my vice as a forming tool. Its an old header fabrication tip the Googles told me about.
On the Left side, the steering box dicated that no more than a 2.5" OD/radii elbow would fit around the coupler.
But when all was said and done, it fit fine but I wasn't happy with the smallish opening that the 2.5" provided. I don't have much choice but its not ideal.
Since I had a bit more room on the right side, I wanted to give a larger diameter a go. I mocked up a 1:1 paper cutout of a 3" OD; 3" centerline radius elbow to check the potential fit. Looked decent
I formed the shape in the elbow with my forming die just like I did with the Driver's side. Then I milled the flange opening to fit along with a lot of hammering, banging, bending and cussing to get it fit
End result is not too bad. The larger 3" of the Passenger side in just a tad larger all the way around than the head port. Once welded, it'll be dead on.
Its fit to the chassis is good too.
Here it is compared to the Drivers side prior to welding.
Here the stark difference in diameter and well as offset from the head. It's obvious the 2.5" is a far tighter fit.
I plan to adapt the 3" back down to 2.5" with this tapered cone from Vibrant
EXHAUST Headers:
I got the Passenger side tack'd and ready for TIG, so i figure a little more comprehensive description of my work.
The 3.6 Pentastar has an odd ball single exhaust port. First task was getting new flanges. The flanges were cut from 3/8 stainless to these dimensions
To get the weird shape formed, I used an old Catalytic Convertor flange cut in half and weld to my vice as a forming tool. Its an old header fabrication tip the Googles told me about.
On the Left side, the steering box dicated that no more than a 2.5" OD/radii elbow would fit around the coupler.
But when all was said and done, it fit fine but I wasn't happy with the smallish opening that the 2.5" provided. I don't have much choice but its not ideal.
Since I had a bit more room on the right side, I wanted to give a larger diameter a go. I mocked up a 1:1 paper cutout of a 3" OD; 3" centerline radius elbow to check the potential fit. Looked decent
I formed the shape in the elbow with my forming die just like I did with the Driver's side. Then I milled the flange opening to fit along with a lot of hammering, banging, bending and cussing to get it fit
End result is not too bad. The larger 3" of the Passenger side in just a tad larger all the way around than the head port. Once welded, it'll be dead on.
Its fit to the chassis is good too.
Here it is compared to the Drivers side prior to welding.
Here the stark difference in diameter and well as offset from the head. It's obvious the 2.5" is a far tighter fit.
I plan to adapt the 3" back down to 2.5" with this tapered cone from Vibrant