I Built a Crazy Header Using Simple Tools

[@TheFabricatorSeries]

Use promo code TFSTUBE75 to save $75 on your first tube order with Xometry. The offer expires 10/31/24. Limit one per customer. "Design Best Practices for Tube Bending and Cutting" webinar on 10/10. Register here: xometry.zoom.us/webinar/register/4517264996543/WN_q0qMJU_pSh-fmid5XvRNKw

[@husmanraceengineering]

30 years ago I started with a Tig welder and a saw. I’m now 54 and still fab 7 days a week and love it. 30 years of hard hard work I now have amassed 2 shops and millions in tools. To the next generation use and take advantage of the of the technology available to you. Work your ass off and you can leave this world feeling like you’ve accomplished something.

[@chuckflitton5293]

Built a few sets of headers 30 years ago. You guys have it easy. Good Job. Tech Is the Bomb!

[@nealesmith1873]

This is great! Very good to know how to get things made even when they require abilities beyond our own.

[@novarocker247]

This is awesome. I’m building a 67 Mustang and it gives me so many ideas to actually do what I want.

[@tryaluck]

You can make a pipe clamp for holding pipes together while you tack them using a locking plier clamp, or what we call mole grips in the UK. They normally come with a swivel plate for clamping flat surfaces, but if you cut them off and weld two small pieces of angle bar on they work well for clamping round surfaces like pipe and bar. You can purchase factory made pipe clamps, they come in all sorts of designs, some are bulky and quite expensive. But majority of pipe fitters like myself just fabricate our own, they are cheap and less bulky. And another tip, when you mark the pipe with a marker for lining up, use a thinner marker and do multiple lines, it will help you to be more accurate.

[@ilsenote969]

I run a small shop with repairs and fabrication or anything and everything small (that other big companies in the neighborhood don't want or ask crazy price for) and i use these services regularly. Lazer and flame cut, rolling and bending, also milling and boring. I recently bought a lathe and it is a huge time saver to have that. A little millimg machine is my next purchase, but thats all i can fit in my shop and still have space to work around it. I have a band saw, drill press, welders all types, a table and all sorts of clamps, ... the only things i will keep outsourcing are cnc cutting, rolling, and bending (tube pipe and plate)

[@cam.venice]

Thanks for showing us Xometry. Who cares about the other tools being used. They were common tools like you said.

[@joelgeorge962]

I've been subscribed to both TFS and Garage Fab for a long time. I can confirm neither Aaron nor Justin are tools. They are both great educators!

[@RambozoClown]

After building racecar headers from U bends back in the day, this is just wild. What I would have given for access to services like this.

[@TheFabricatorSeries]

This generation is so lucky to have all this at their disposal. I could have been so rich!

[@sammartinez4244]

@@TheFabricatorSeries I agree. Wish we would have had the Net & YT in the 70's. I have always spent so much time calling companies for product information and catalogs. Research and phone calls took a lot of time, then.

[@krusher74]

@@TheFabricatorSeries But the fukboi fabs are still messing about with 10 pie cuts and hours of welding for a bend and they seem to think its "cool" I was waiting for somoeto finally make use of CNC benders to cut the welding to as little as possible, I;m not surprised you were they guy to do it.

[@SuperYellowsubmarin]

I hear you. I do prototyping for aerospace and use Xometry or Hubs / Protolabs a lot. While I sometimes regret not giving much work to local subcontractors, the time saved on getting prices, placing and tracking orders, plus being sure there is always capacity and lead time vs cost balance, that's just too valuable for me.

[@vitomartinez3193]

Thank you for the video @ Thefabricationseries. I have a small shop and threw the years i have purchased welder,plasma cutter air compressor, as time progress working a normal job to fund everything, if i were starting a business and have the basic fab tools have this company bend the pipe for me and i have to assemble weld and make something that requires complex tools, but after time if you make quality good looking parts and eventually end having enough to buy my own equipment. What i like is that F.S. he explains why and how to do it how he started because proper equipment cost thousands of dollars but if you love it theres a way. Beautiful header by the way.

[@joannehart9624]

I think it's amazing that these small-batch shops have become available. Maybe I don't need 500 units, but really only a couple. Now we have access. Yes, the price is more than mass production, but that's the cost of building "one off" items. Shops like Xometry and Send Cut Send enable fabricators and hobbyists to bring their visions to reality.

[@ScootyPuff_Jr]

I don't think Xometry actually makes anything. I know they post machining work to a job board for machine shops to accept and going by what Justin said about Xometry rejecting that tube from the manufacturer, I would say they do the same for tube bending. Xometry is a middle-man company with fancy software, like Doordash.

[@DR0NE_BEE]

Morpheus of the welder world!! "Welcome to the real weld". 🤘🏼

[@jcarlile8279]

Justin I’ve always loved these low tech builds. Thank you again for showing more of them.

[@joemurray8902]

I think the non practice before on the new type of material is realistic. I think a lot of people will just grab the torch and "lets see what happens". Really cool company.

[@cpcoark]

I hope they share some of their customers reactions to your build. It truly isa showpiece.

[@chuckflitton5293]

Thanks for being real! And not hiding anything.

[@aidaneckart5054]

The tools you're using, EVERY fabricator I think would have. I really like this. I know I'm late to the party on comments but the down to earth fab and cool out of the box projects is what brought me here to this channel all those years ago and I love to keep seeing it. That 3D printed collector is the COOLEST thing. I was curious on how weldable it would be or if it was a bit of a pot metal concoction.

[@MattSoppa]

This is exactly how conduct a lot of my business on the product side. Xometry and other laser cutting and bending devices. 👍🏼

[@bigviking0001]

Dynamite!!! and very timely for me. Have had a "mode of transportation" that I have been using for 7 years that was made from a chassis I got from China. Long story, but it finally gave up the ghost due to internal rust. I need to replicate what I did from some 4130 but, no longer have the tube bender that I had, Sounds like Xometry might just do the trick. Thanks!!!!

[@tazeat]

This was cool. Definitely an I bet I could do that moment as a hobbyist that brings a smile to your face.

[@terrypellam6989]

That’s a nice piece! Enjoyed the video! Xometry looks like the do pretty good work also. The 3D printing is changing the game.

[@jaimeortega4940]

Good job on the design with SolidWorks is an extremely robust (if not somewhat confusing at times) CAD program for parts with some simulations. Xometry looks perhaps expensive but pretty cool.

[@thejohnnybob]

It may be expensive, but what's your time worth? (Meant to be legitimate conversation, not a troll)

[@jaimeortega4940]

Right because like he said he wasn't able to have his Dyson vortex made until now. So still cheap.

[@dr.feelgood2358]

as far as business goes, that is a huge advantage to have all your parts made and shipped ready to weld up (almost). for the hobbyist it takes some of the fun out of doing it yourself...but not everyone has $50K to spend on equipment for self-enrichment!

[@madderote7103]

Like that header! That's a work of art!

[@bigjondrags]

What was the cost on all those parts?

[@mike_onevia6465]

yeah i know right, craazy build simple, cheap with little to no tools, bet my guys 30k in debt sold his mother to a slaver, solds a kidney to zukaberg and re-mortgage the family home... click bait....

[@k.thornton3469]

Shhhh!😂

[@krusher74]

Even if there are "expensive" you still have to compare it to time/gas etc saved welding.

[@bigjondrags]

@@krusher74 I agree, but there’s hours of cad also. I was genuinely curious on cost

[@paulmaigler289]

Great video and information, great to see ManKandy giving a hand. I really enjoy his videos as well, always lots of information and inspiring ideas from you guys!!

[@TheGorf]

I can super appreciate all of this. And I have always had great respect for your skills and your work and even took you classes in Vegas. My challenge with videos like this is that it's so beyond what I can do. Solid works is $8k and then you mention that the other software is "only" half that price. But $4k is still a nearly unreachable expense for me. Even just now trying to learn Fusion360 has been a challenge.

[@stephen271]

Thanks again for showing another top video. Really enjoy your channel

[@jasoncampbell4723]

ManCandy is definitely a Tool!

[@zeroswings2]

I've used Xometry quite a bit...buuu-ut... I did NOT know they offered tube bending... knowing that is a HUGE game changer

[@nesmio7378]

What was the grand total for this from xometry? Was that ever mentioned?

[@Hopwhisperer]

Never said but it looked like the header flange was $156 soooo

[@novarocker247]

@@Hopwhispererand that’s not bad. Stainless and your design with 3d printing.

[@mrlaxman915]

prepping the 3D printed stainless by sanding down the joints to bare shiny metal helps a lot and should make it weld more like stainless tube

[@courier11sec]

Killer piece. That collector is siiiiiick! I probably would have bolted the flange to the table then as long as you made sure your primaries were all square and in the collector I think you'd be good. I don't think anything you used would be unreasonable to expect a person willing to take on this job to have. Small batch mfg services like you used here are huge for expanding the capability of anyone who wants to build pretty much anything. Good stuff.

[@chevetin96]

Crazy I saw that header at IMTS this year!

[@nothingtoseaheardammit]

Hey. Paste tastes good.

[@courier11sec]

Can confirm.

[@TheFabricatorSeries]

@nothingtoseaheardammit I have reviewed your channel. I do not see any videos of you tasting paste and stating it is good. (please don't eat paste for a reaction from me)

[@courier11sec]

@@TheFabricatorSeries they are member only.

[@michaelnelson7305]

Nice job, looks great

[@stevemaher7863]

Nice work. Great support from Aaron.

[@JM-cg3ps]

Anybody else notice the dolly/zoom shot from Jaws! Nice work ManKandy!

[@TheFabricatorSeries]

That was a nice surprise to find when editing. I had to keep it in.

[@_FJB_]

Should have used a megaphone! The collector is something I've also thought about years ago but forgotten about but nice to see pop up now with 3d printing!

[@ianm432]

I have an idea about using a miter box for woodworking for cutting stuff using a long sawzall blade in place of a bandsaw. I have a grinder and I'll still use that but i have a bunch of nice Diablo blades that are worn in the usual spots and a miter box would stabilize the blade past the midpoint where they are still like new. I've decided to buy a tig and build an exhaust for my HD Dyna vs. buying one for 1400-1800. After I'm done, I'll have an exhaust AND a tig.

[@biy_buildityourself]

Holy smokes, we did a twisted collector just like that for our 5 to 1 merges on our V10 build! Great minds think alike!! We wanted to get all our pipes bent as well, but couldn't get it to work out. Really cool to see it can work!

[@OndreaS123]

i've wondered how to do a twisted collector for the last 15 years for the same reasons. the big question is- does it make a provable difference?

[@burtonr]

This is cool! I've been dreaming of being able to build out a set of custom headers, but no idea how. I'd be really curious to see how that printed part holds up to the heat, and how well that vortex design works. Xometry and SendCutSend means you don't hardly need any tools any more!

[@fopeezy3097]

Man that is SO cool

[@dc85337]

OK - another negative comment That is an amazing piece of work and workmanship - even if it was for show, which is too bad, as I'd have liked to hear this actually run!

[@steffore1]

Superb job 👏🏽👏🏽👏🏽

[@Laura-wc5xt]

Always great Justin…Paul in Orlando

[@dominicalbrecht7039]

Damn that build is awsome..we dont have anything in australia like the companies you are talking about so i have to do all my builds from scratch..companies like this would be a game changer for me for sure..love it..

[@Bosbulls]

That is so true mate. We have even less of these companies in South Africa. And those that are avaliable, are crazy expensive. Luckily I found one in my town that is willing to do small laser cutting jobs without breaking the bank.

[@krusher74]

well there is your business opportunity.

[@ThisIsToolman]

I made a pair of screwy down pipes for my shorty headers using trial and error and PVC pipe as my model. I used pie cuts to form the bends in both the PVC and the steel. I used the finished PVC to build a fixture for the steel. I used an acetylene torch to assemble the pieces. Turned out great. Not as pretty as mandrel bent tubes but it only cost me the price of exhaust tubing and PVC pipe. The bends couldn’t be mandrel bent anyway. Good job, though, despite the click bait title. Your online outsource is particularly useful.

[@TheManCaveMetalFab2580]

Hey bro, excellent videos I’ve been watching you off and on for a few years. I’ve been doing mig Welding for roughly 15 years with no real training whatsoever building mini bikes and small projects. I decided a couple years ago to get into Tig Welding and got one of those primeweld TIG welders which turned out to be Not a good choice for a beginner TIG welder. I sold that one and I’m about to get something a little easier to use a azzuno 200 amp 110/220 TIG welder which of course is not a high-end welder, but will do the job nonetheless!! after watching one of your videos. I quickly learned that the gas used for mig Welding and TIG Welding is very different. 100% argon with aluminum 75% argon 25% CO2 for steel however for TIG welding 100% argon for aluminum and steel that I didn’t know lol I will keep watching your videos. I have a lot to catch up to do!!thanks for the videos. I very much appreciate it!!!

[@brucemadden1626]

Nice to see the blow-up diagram(4 minute mark)that Adam Booth just made for you. Let us know what "plastic injection mold" you plan to use it for.--thanks.

[@johangroenewald6406]

Liked the video! Good advice

[@arndtcraftrace9522]

Since you have a fixture table there (you're using as a "tool") that has known dimensions ( Model table, use in assembly with header), you might as well had Xometry print you a few fixtures, as a means to fasten the printed locating fixtures to ( using 16mm shoulder bolts, and nuts on bottom of table) With such a simple one/two piece runner, you could get away with a single locating fixture for the just the collector. Much easier than fumbling with the tubes in space. This is how I approach header builds, or anything within the tolerances of an FDM or SLS print. Generally, hard (machined) tooling is rarely needed for builds like this. Just an idea...

[@spartacus09ful]

Could this be done with just mandrel bends and tube? Great video, I aspire to be as good as you!!

[@White.Elemant]

I didn't catch any info on price, other than the flange costing $150. So I'll venture a guess the whole set was $1000. Feel free to correct me if I'm wrong.

[@akschu1]

Looks great, now... where can I send a cad model and get fiberglass parts made? I could build this, but can't quite figure out composites.

[@RambozoClown]

For now you can do glass filled composites that can be 3D printed. Fiberglass production doesn't lend itself to one-off manufacturing unless cost is no object.

[@akschu1]

@@RambozoClown I am aware and my prototype is 3d printed, however my final part needs to be able to withstand some heat, so it really does need to be fiberglass or carbon fiber.

[@RambozoClown]

@@akschu1 You can do traditional hand layup using 3D printed molds, or you can directly print heat resistant carbon fiber with selective laser sintering.

[@akschu1]

⁠@@RambozoClownwhere can I get a quote on laser sintering? That sounds like an option. The part is an aircraft nosebowl.

[@jaimeortega4940]

Really cool the made your Dyson part!

[@guyfranks4354]

This video is extremely helpful for me. I am looking to build a set of headers for my '92 Isuzu Rodeo equipped with the 3.1L V6. My dilemma is that the stock exhaust manifolds have 1" thick flanges with some studs that are used to mount the Alternator and the AC Compressor to the engine. Finding collectors is also part of that as well. THANK YOU for this video. It will help me alot! I find your videos very enjoyable and informative. I anxiously await the next one.

[@Phabian_Phabrication]

Fun fact, i bought and use that exact caliper for aerospace manufacturing and when i weld in my shop, it’s cheap but works 😅

[@alessandrobindella5650]

Hi. How did you go about making the 3D drawing? Have you scanned the space where the tubes are inserted into the machine?

[@mchiodox69]

very cool...well done

[@psychoholicslag4801]

When theorizing the twisted merge collector did you factor in pressure pulse tuning? It looks very cool but I'm dubious about the function. The reflected wave may be weakened reducing the low pressure reflected wave weaker leading to lower output. Would very much enjoy some real world testing. You do some incredible work and making it look easy which means you're very good at it. As always, good job.

[@shawnlindemood6678]

This is an excellent video to show some capabilities of Xometry. I've tested several parts for pricing between brands X and brand SendCutSend. The parts I need made are fairly simple and an example is brand S is (2 x part with bends) = $55. With brand X the same (2 x part with bends) = $148. Prototyping and onesy/twosy parts don't seem competitively priced and I so I won't compare part quality. I think this would have been an even better video if you went over how you designed the header and/or how you uploaded and selected materials. I understand that makes a more involved video but that would add value to this. This is an effective ad and I love the header. We don't get an idea of the pricing scheme for the parts. We don't get and idea of trade off basic tools and money spent on premade parts. I like the swirl collector and I like that they can do that. The guys at Build It Yourself channel had swirl collectors printed for their V10 project.

[@Will-No-Co]

Oh yes he is a tool!😂. I’m already subscribed to his channel. He’s got a great video on a Watts link.

[@RaysonsExhaust]

Great watch 😁👍 but.... having an extra set of hands is definitely cheating... the greatest tool known to man, is a well trained pair of hands.. 😉 I make Vintage exhaust systems and use sand bending and hydroforming to get around alot of the bending issues. But it takes lot of practice to master to dark arts. 😊👍 Ben at Raysons Exhausts

[@bps.1]

i would like to have two of those merge collectors for my headers ,how much are they or do i need to get the demintions from you and have the company xometry make them for me

[@magic4221]

Hey, Justin, I just watched a couple of videos about hand held laser welders. First,,have you ever used one,and second would you recommend the use of them over mig or tig? Please I need your knowledge.

[@goodmanboattransport3441]

Of coarse a caliper is a tool, but if you are into this kind of work, who doesn't have that

[@ThisIsToolman]

Did we count the fixture table as a tool?

[@chuckflitton5293]

OH! looks like a couple of tough welds

[@AnonymousBrain65]

Can we please hear it run on something! That collector is sick!

[@goodmanboattransport3441]

A company that is on Xometry 3D printed my prototype high pressure fuel pump for like $40, it was such a deal compared to a local provider

[@southwestaudiovisual5069]

Good day - First time caller, long time listener. Thank you for showing us Xometry. Fabrication is a side part of what I do. I have a pipe bender. It's an old-school manual beast that I use a 6ft breaker bar to use. No CNC...using sharpie marks to make sure I bent the dang tube the right way. If anyone is looking at starting in bespoke fabrication, remember to include "opportunity cost" in your ROI breakdown. It would have taken me a couple of days, if I was LUCKY to nail all those bends for a header design. My labor rate is part of the quote, however, it's hard to charge by the hour if you're slow at something. If you add in the time it would take you to do the bends, cuts, etc before the weld, IF you had the machines, there is a use case for Xometry right there.

[@anthonylimjoco5958]

tape and cal are standard tools. You really can't do anything without em. As a wanna be fabricator, I use any tool to get the job done. I've bought a used a habor freight vertical band saw for wood, brought the rpm down for steel and up for aluminum. Cuts straight and running strong, don't get caught up on brands just get er done and save up.

[@christophershafer5615]

I'm not through with the video yet, but that video(s) on the back walls method was very neat! Returning to ask if it would be possible to make the vortimerge if you made laser cut profiles on bent tubes?

[@Zivon23]

How do I get that spiril collector?

[@mikebates7234]

What does it fit ? It looks pretty but try making it fit a 37 ford with a 302 + 5 speed

[@jacobjames1171]

How do you make a complete seal at the collector with the tubing being so close together? I can't see the welds being 100%. An honest question, I don't build exhausts.

[@TheFabricatorSeries]

The tubes are welded from the inside up to a certain point that is very close to the collector. A hot weld blends them all together to seal it.

[@ismaeelseedat5892]

​@TheFabricatorSeries Apologies if you've covered this already, but if you could do an in-depth video on this particular part of the process that would be awesome 👌🏼

[@TheFabricatorSeries]

@ismaeelseedat5892 I have never covered the topic in great detail, but if the situation presents itself, I'll make it happen.

[@cesarortega6615]

I see you tried to purge the back of that plate you welded to the 4 tubes... how do you use a tig with mild steel? That's what I'm thinking they are making the rear subframe reinforcement plate for the bmw e46. How do I prevent the back of the plate from sugaring up or oxidizing when you are welding those plates to the body. I'm not expert to weld those with tig but I don't want to spend too much money on a mig

[@chaseweeks2708]

Really curious about the cost on that collector. I bet with a few tweaks you could make the collector one of the easier parts to weld up rather than notoriously the worst. Like, cant the ports out at maybe a 22.5deg angle and spread them apart just a bit so that you've got room to work between them, and just add a 22.5deg bend on the end of the exhaust primaries to match. Probably take up an extra two or three inches of diameter in the engine bay, but it might be a lot easier to weld and, more importantly, look friggin sick. On second thought, since we're already 3D printing parts, could print a center spike-looking piece that welds to the inside 1/3rd of the radius of the primaries, welding without the rest of the collector in the way. Then weld the collector on, and only need to do one bead all the way around. Just a thought. Definitely going to have to keep this in mind for my own projects down the road (if I ever get back to a place where I can have projects again). Thank you for all that you do. Edit: I wouldn't even consider myself an amateur welder, so if I do a project like this I will probably go with ordering some 3D printed coupons to practice with instead of Leroy Jenkins'ing the final product. But also could be a product to consider stocking in the online store for all three people that would buy it.

[@tankerboysabot]

I saw the part that Abom79 made for you.

[@TheFabricatorSeries]

His work is so clean. The way this part snaps together so tightly is unreal for a hand machined part. I love working with him.

[@brandonculver2403]

Have you ever used a piece of brake line for a purge line extension or something else that would be less likely to melt. I understand the minimal tool idea, but technically, it wouldn't be a tool.

[@fredfeldt5329]

You are amazing and you have actually taught me to tig again after just barely welding when I was much younger 😊

[@andyb7754]

This reminds me of the good old days when you fabricated out of your garage. Thank you.

[@LiveForGLory]

Hey Justin, I've watched this video a couple times now because I'm just a beginner fabricator hobbyist ( supporting my other hobbies) and I'm needing to replace the rusted out headers on my Jeep that I cannot replace by just purchasing. Is there a way or a service that I can 3D scan my current headers with my phone and have someone create a CAD file from that?

[@constantproject1450]

As others have said it’s super cool but how much was all of the bending and everything? That’s atleast what’s steering me away from doing something like that when I could take the time to buy my own tools

[@SteveWrightNZ]

The vortex would normally create a swirl choke point. Aviation circles go out of their way to avoid inadvertent vortex creators, for induced drag reasons.

[@DieSnider]

Would be interesting if it where printed with DED instead of PBF. then it might not have that muddy feel, because you would weld in a weld.

[@kathysarmcandy1992]

How much for all the scraps, to practice?

[@TheFabricatorSeries]

@kathysarmcandy1992 If you're local you can have them.

[@rickybailey7123]

How much would it cost us to do what u did ? I didn't hear u say that !!

[@TheFabricatorSeries]

It depends on the design, materials, and quantity. There's no universal answer.

[@TheObserver567]

How much was that 3d printed piece?

[@attilaleventebocsi4633]

finally met someone who uses onshape just like me :D

[@TheFabricatorSeries]

I'm really enjoying it. I love being able to use it anywhere and the frame function and frame trim is so smooth. The one thing I miss the most from Solidworks is 3D sketch.

[@betterbackwards2701]

Loving the combination of skill and high end modern tech. You's showing a massive future of possibilities. Thank you TFS.

[@chrisdonner2910]

I wonder if the blasting of the 3D printed part gave you trouble

[@RambozoClown]

I wondered the same thing. Maybe sanding the area to bright clean metal would have helped.

[@AUMINER1]

very cool

[@carlbyington5185]

Can you 3D print stainless, or metal ???????

[@kenselleck2414]

As much as I have learned from you I think we can float you a few extra tools.

[@Drunken_Hamster]

Please consider filming in 30fps with a 1/50th of a second shutter speed for this type of content. Be sure to activate shutter priority mode for your auto exposure so it won't change the shutter speed from this setting. Also, grab some ND filters for outside otherwise if you're using a camera without an adjustable aperture (such as an action camera) then they won't be able to get dark enough in direct sunlight with the shutter speed locked. The shutter speed NEEDS to be locked so you have a natural-looking motion blur, which is a huge factor in how pleasing your footage looks, even if you DON'T change the frame rate. If you're dead set on the low frame rate look or if you have a videographer who chose these settings I have another trick setup for you, especially if you like to use slow motion AND don't want to change camera settings in the middle of shooting in order to switch to slow motion.

[@AdinSLaboy]

Great video very informative 😮 wow brutal i was thinking if I can do that, i got a toyota tercel 😅 the i know for sure the has a lot of restrictions in intake and exaust but the mayor its in the intake and it's almost impossible to found a header and IM i thinking 🤔 if I can make that happen my car it's gonna go good on 🛣 because everyone else pass me

[@kennethtalbott2233]

i can't see for the life of me how you could weld all the way around the four pipes into the splitter. looks a nice job though.