I've done lots of fabrication and custom parts on previous projects(mainly Jeeps) but building my MKIV has definitely created a bunch of "first time I've ever done that" moments. I have built exhaust systems in the past but always used off-the-shelf headers as a starting point. That wasn't an option for me based on engine choice this time so I decided to tackle building custom headers.
Buying the ICE Engine Works "lego" builder kit would have been nice but ouch on the pocket book. Instead I just started with a bunch of Schoenfeld Headers j-bends in 1-7/8" 16 gauge mild steel and I created a custom chart with all the common angles I might use. I cut a little tool to help scribe lines around the tubes and just started with a few chop saw cuts to see what angles might work. It really hasn't been difficult, just tedious. In the end, I'll most likely use a total of 9 j-bends to complete both sides, but as of now the driver's side is done using four and a half tubes.
I used a 1/2" header flange to resist heat warping and also tried some other tricks to keep things flat. The 4 port side pipe flange is from Factory Five and a local muffler shop stretched the ends of my 1-7/8" tube out to the 2" holes in that flange. You can also see the aluminum jig I created to hold the sidepipe and flange in the correct place while I was working.
I'm pretty happy with how they turned out considering it's a first attempt. The passenger side should go quicker and also look nicer. I'm planning to paint then wrap the headers instead of ceramic coat. Wrap has way better temperature control but definitely doesn't look as nice. I also know they'll rust out faster but one of my Jeeps has had wrapped headers for 10+ years with no issues and they were cheapo 18 gauge headers. Once I have an issue with these I'll just make another set and hopefully be even better at it a second time....
On to the passenger side!
-TJ