AU XR8 Headers - cleaning up header pipes - Ford Forums

JC-XR8 · 06-30-2004, 18:35

Guys, i was talking to another car enthusiast yesterday about my XR8. He reckons he has a mate who owns an AU2 XR8, and instead of fitting aftermarket headers, he took a die grinder to the standard factory ones and cleaned up the ports. Apparently, the standard headers have a lot of welding on the inside of the header pipes (where they join the manifold which bolts to the head). Flattening out the weld "lumps" apparently increase air flow through the headers and is worth up to 5rwkw.

What I want to know is has anyone done this - if so, did you notice a difference.

Can anyone who is mechanically-minded tell me if this is worth doing - I would have thought that die grinding the welds would weaken the headers.

Thanks guys - I know this sounds like a bit of a stupid question, but if it works, it is free horsepower and I won't bother with extractors (can't afford them anyway).

Bluedriver · 07-01-2004, 17:22

JC, I was just shown the differences the day before yesterday while I was getting new extractors fitted to mine.
My exhaust guy had a Series 1 OE header he showed me and man are they small ports (even compared to my Series3 OE headers) for the exhaust to get through and yes the weld would make some impact on the exhaust flow. They are not timed as they say in the game (I am not an expert but was explained this and it makes sense) meaning each pipe are not the same length or similar by the time they come in to meet the collector. (Aftermarket ones are,thats why the difference is felt)
It would be a fair bit of work and time (but you seem to have plenty with all the mods you do lol) but I'm sure it would help your exhaust flow a little.
Then again if I decide not wanting to keep my Series 3 originals I'm sure we could come to a fair price for them,because believe me if yours are the same as I saw compared to mine its "chalk and cheese"......Ford did a half a good job with the Series 3 I see now, don't know about S2....
I say half job because through connections and advise got my hands on a latest design Genie Headers, yes against the norm what everyone is buying in brands but I thought heck they were once the fore runner in this game (meaning they are not dumb),they let the others take more market share and didn't advertise as much.
I understand they are getting serious again. Well my car is transformed,taken away the lag/sluggyness down low before 4grand where I was most disappointed while in traffic (I am in Sydney) it definately pulls better now and man the sound is horn.....
Going back to half job,yes they put better headers on Series 3 but why not do it right the first time.
Sorry for the long post ppl and hope this helps you out JC.

RaceCraft · 07-01-2004, 17:53

If you have the time, pull them off and have a look see, compare it to the gasket for overall I/D and any MAJOR dags...When you have them off the car i'd be more looking for kinks and flattened bends..Igntions factory headers were crunched very badly on one cylinder..
IMO they were welded from the outside of the flange so you'd only be dealing with whats known as 'pentration' of the weld.. GRinding that off would not harm the strength of the header provided you stop before you start hitting the parent metal, ie the tube....

RaceCraft · 07-01-2004, 17:59

Quote:

Originally Posted by Bluedriver

They are not timed as they say in the game (I am not an expert but was explained this and it makes sense) meaning each pipe are not the same length or similar by the time they come in to meet the collector. (Aftermarket ones are,thats why the difference is felt)

I think you meant TUNED.. Tuned length headers use the same length of pipe but IMO not all aftermarket headers are TUNED length

JC-XR8 · 07-01-2004, 21:27

Thanks bluedriver and tibbo. Bluedriver, how much would you be after for your series 3 headers? If they are clearly better than the series 1 standard headers, then I could be seriously interested (for the right price).

This would also mean that I could get them off you, clean them up a bit over a period of time, and then fit them to the car once I'm happy with them. The best of both worlds, really.

Tibbo - all factory Ford V8 headers have a kink in them for the steering something or other. It is quite bad, so perhaps the ports are not the least of my worries, but I figure if I can clean them up at all, then it may just give me a bit more punch anyway (kinks aside).

TICK4D · 07-01-2004, 22:31

I don't think it is worth the trouble, yeah it will help air flow but it is the press bends and joins that rob the exhaust of any decent power.
5 rwkw you would hardly notice and be used to it before the end of the street.