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No problem with hoarding - I was like that with early Land Rovers till my wife made me clean it all out.
But I 've just bought a farm and I am starting to see the abandoned ones and it is putting bad thoughts in my head!

John

Farmer...Hoarder....who's to say really?

OK OK OK now on to fun stuff

So I am planning to make my first set of headers. The ports are not a nice round shape...they are not even a nice symmetric shape...

I plan to CNC the flange to match the exhaust port. I am also planning to machine a die to crimp the snout of the header to match the port. Does anyone out there have a recommendation on literature to educate myself on header tuning?

The head is not ported, and consensus is that the stock zetec is not a good flowing head by any measure. I plan to get a second head down the road to port and tart up. For now this exhaust will be put to waste on a bone stock head, so it is more for the practice of making a stainless header than anything.

I got a free pass at work to do machining and I plan to abuse it by making car parts....

I reckon there must be 10 pages worth of exhaust tuning talk in Mark's V12 thread, not sure how searching goes on here.

John

Attached is a screen shot from a program called pipemax that calculated the basic header parameters for you. If you can find and post your numbers for each variable I'll run it for you.

Another way is to simple look at what is being sold for that engine and copy it.

Many stock heads have outlets that are too big for the desired header tubes. The standard answer is heat and beat the tubing to fit the flange and semi-smoothly transition smaller (or bigger if that is the problem). This transition is not as critical as your brain will try to convince you it is, the tube size, length and collector are what matter by far the most so just do the best you can .

There is a thread with lots of pics and thoughts here:
http://speedtalk.com/forum/viewtopic.php?f=1&t=41836

some thoughts are good other not so much but lots of pics so worth a look.

To follow Mark's critique: Single shear?!? Eeeeewwwwwwwwwww