S54 Header Design talk

[3staxontheradio]

This is a sketch of an alternative layout looking more like the way achillies did it. Right now its 575mm +/- 4mm primary lengths but that can be adjusted and cleaned up with some stuff like bend centerline lengths. I like how organized the two merges are and they clear the trans tunnel and lollipop heat shield perfectly.

I'm planning to taper the whole way gradually but also switching a single step would be easy enough as well.

At the moment I'm just laying it out as quick splines in 3dsmax. I'm going to transition to actual cad soon. Likely fusion 360 so more people can edit or modify for their needs but I'm much faster in 3dsmax so I use it for quickly testing ideas.

Bry5on Do you have any kind of engine bay scan for the header packaging area for an e46? This fits the 36 well but I think a few spots on the E46 are actually tighter.

[Bry5on]

Woah that certainly looks like a bundle of snakes! I think I sent you some engine bay scans and a scan with an s54 in it via email. I also have a couple fusion 360 models that I can share access to that have my header designs and scans in there simultaneously. Let me know when you switch and what email you want me to send the collab invite to and I’ll figure out how to do it. It’s a bit of a pain to design splines in fusion but is doable.

I don’t think your e36 design will clear the e46 with shear plate based on first glance. If you want to export STLs, I can bring them into my model for collision analysis as well.

[3staxontheradio]

Okay I'll look in my email for those engine bay scans. I can pack the primaries a little tighter too. I left space so that diameters can be easily increased but this is a 46mm OD right now. I want to rework #6 because that's a lot of turning before the merge. I think you were sharing some stuff with me through fusion but the link expired or something?

[Bry5on]

Okay I'll look in my email for those engine bay scans. I can pack the primaries a little tighter too. I left space so that diameters can be easily increased but this is a 46mm OD right now. I want to rework #6 because that's a lot of turning before the merge. I think you were sharing some stuff with me through fusion but the link expired or something?

Looks like I shared everything through the fusion link. It's all in the same link. Link appears still good on my end and is password protected


Likewise if anyone wants to get in on the CAD action, PM me for details - don't want the file opened up on the public internet as it's still being edited

[digger]

I want to try to do the merge as a slip fit so it can be swapped out without dealing with the cost of the whole header again. I'm unsure if tolerances will make that possible? I might be able to print the merge with the inner walls with extra material and then machine them to whatever it needs to be based on the actual final diameter of the primaries.

The AR and choke are things I have been thinking about (also collector diameter). It would be shame to oversize the collector and lose some bottom end on my stock engine or have other features get in the way of the basic concept. A 52mm choke is so conservative though, total stock collector is only 55mm. I think the manzo headers are a copy of the super Sprint V2 non-step headers. Looking at those super Sprint headers - they step the ID down for the slit fit joint into the section one of the exhaust so I think super Sprint is also using about a 60 mm collector. Has anyone posted dynos of the V2 super Sprint versus something more conventional like Euro headers or the Megan racing which are a decent looking clone?.

Also check out these achillies Motorsports headers. Long primaries and merges placed in line. I'm going to attempt to measure out the dimensions based on the photos.

https://www.achillesmotorsports.com/...-p/18-am-h.htm

i am not sure how good or effective sealing slip you could do with 3D print and whether it would be best to do a single or triple piece primary probably the latter with a small stub of tube. it would warrant some test pieces as this would be crucial for being able to do a simple collector swap for testing. For testing perhaps the slips will be good enough but on a long term use once a design was established you could do possibly change to permanent welded setup if the slips weren't sealing and messing up O2. There are all sorts of permutations and combinations.

[digger]

A semi permanent solution could be a little bit of muffler / exhaust putty /cement

[3staxontheradio]

A semi permanent solution could be muffler / exhaust putty /cement

Yeah I was thinking that and then if I'm happy with a setup I could finish weld the slip fit into one piece so it can't leak.

[Cubieman]

S85 headers like infinity/supersprint use a slip on collector sealed with RTV and hardware to keep things tight.

I have run the Infinity headers for quite some time without issue as have many others for years.

These have a slip on collector due to the fact it's nearly impossible to have them fully assembled and then install them, you need some wiggle room.

[digger]

S85 headers like infinity/supersprint use a slip on collector sealed with RTV and hardware to keep things tight.

I have run the Infinity headers for quite some time without issue as have many others for years.

These have a slip on collector due to the fact it's nearly impossible to have them fully assembled and then install them, you need some wiggle room.

Just bear in mind to find the highest temp rating to maximise durability as cherty red headers can exceed the rating of high temp rtv quite easily . It might be an idea to not slightly thicken wall thickness in the slip to manage temps though it does inherently run cooler due to the double wall and thermal inertia . Plus the longer primaries work in your favour