308 V12 conversion begins

I did fix cracks in both upper frame rails at the shock mounts when I first got the car but I never posted pics of anything back in those days…….ahhh wait…I’m now remembering that this was your car I belive.

 

I thought about separate flanges but any headers I’ve have tried to install that were made that way all had alignment problems fitting to the head. I figure I’ll build 4 separate 3 cyl headers the make them a slip fit/spring retain into the merge collectors and hope that gives me the movement I need for good alignment.

 

I may very well end up doing it all with a purge. I was thinking the flux would be really helpful during the tacking phase if nothing else. I put these tubes together being careful that I could get in and grind the back of the tacks clean, but it seems like it would be nice to just flux the joints and not think about grinding and tack order.

 

Only the pile of bits on the floor pic.

There are going to be 6 collectors, four 3into1 and two 2into 1. I’m thinking I want to weld up this header and put the 3into1 on this header next. I need to make a 90 degree turn down and then a 90 degree going back and both of these bends are about where collectors need to be. I think it will be easiest to set the path length by getting one built then match the length on the second and that will tell me exactly where I want the header tubes to end up on the second header.

The front headers will be a much bigger pain to work on, but the collect issue will be much less of an issue I think so my thought was it would be easier to match the front to the back than the other way around. This is why I started with the rear header, that and I’m way out of practice on headers so easier to make tubes seemed a good place to start too.

 

18g, so .049".....it's pretty hard to not have the weld burn though to the inside. About 1/3 have been front only welds with no sugar on the back, I just need more practice I guess.

 

I might try the mig. It's pretty easy to get a cold tack with a mig then I can grind it off when I put some propper tig welds on.

While I was at the hardware store buying fittings I realized they certainly do carry methanol…it comes in a bottles labeled “gas line antifreeze or “dry gas” when you select the $1.99 bottle instead of the $2.99 bottle which is isopropyl alcohol. I should be all set to weld to night.

 

That was my first plan for the easy to hold reason and I got my mig back from my buddy who'd borrowed it…but for some reason went with the tig, I’m not sure why I changed plans....I guess becasue I welded to the flange first and then just stuck with the tig.

I ordered a quart from mcmaster first thing this morning but it’s coming from Chicago so it will take a couple days which is why I got thinking about where else to find methanol. I’m just going to mix up a little bit of flux tonight and see how it goes…. just incase the dry-gas isn’t 100% methanol

 

That's why I'm only going to mix a little to try....because I'm only pretty sure.

 

Tonight's pics look a whole lot like last night's as all I did tonight was weld. I ended up using a purge on the tubes and then fluxed the ID of the tube around the slits I put in and it seemed to work fine.

Tomorrow I'll see about putting a collector on it. I’m almost out of argon but hopefully it lasts thru tomorrow night then I’ll get it filled Saturday morning.
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I would have never thought to look at a pharmacy. Methyl alcohol is pretty poisonous stuff, what on earth would they use it for?

 

It’s often just a question of practice. Buy a welder and start welding stuff and know you will get better. I very honestly look at my welds to this day and wish I could weld properly.

Last night looking at this 1st header I was thinking I should have started on the front header that no one would ever see instead of the rear one that is right there when I open the deck lid. I must have had to re-grind the tungsten 100 times last night. I was blaming it on not being able to see because the lens in my helmet is too dark for this low power work. The truth is I’m just out of practice…..but I just ordered a new helmet.