Header Tubing Fabrication Tips

When I started my home built twin turbo car I had to do a lot of firsts, one of which was fab up exhaust tubing, charge piping, and make header modifications in order to meet my goal. It quickly became obvious that this type of fabrication was no small task to a beginner, so I had to find a way to hold any given piece of pipe or tubing together for fitment but I needed it to be able to be taken apart and reassembled without a ton of time lost.

Enter our good buddy masking tape, I would simply position a piece of tubing together, secure it with the tape then after a few trial and error sessions when the correct angle was accomplished I would take a razor blade and cut out a small diamond exposing the tubing where it joins together and voila a perfect spot to tack weld things in place. This process was repeated at least two more times then the tape can come off completely for final welding.

This process may not be new but it certainly helped me out and it can be utilized on any type of exhaust work, charge piping, and header construction to save a lot of time and frustration.

1. I'm using this straight joint for ease of demonstration.

2.Masking tape installed, firmly holding the two pieces together but can still allow easy disassembly for adjustments.

3. Use a razor blade to cut the tape and expose a tacking area.

4. Then you can tack pipes together while retaining the positioning of the pipes.

5. Repeat the process around the tube until you get a solid tack. Then remove the tape and weld the joint completely. I used pipe instead of tubing on the headers to help support the weight of the turbos, but the principle is the same. This took quite a bit of removing and resetting in order to achieve the correct angle.
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Check out my Zephyr Twin Turbo here.

Awsome post. Never thought of masking tape!

When i did my headers all i could think of is hose clamps. Trouble is you cant tack them when its calmped. However they do have more strength to mock up a complete assy.

Good TIP!

Glad to hear you like it, I was beginning to think it was a silly post that shouldn't have been made!

For headers you may want to think about these parts from Hooker



I have used them for a couple of builds and they work very well.

Holley Performance Miscellaneous Components Products

Not expensive either , 20 to a package

Hooker Headers Alignment Weld Sleeves - JEGS

I do like the masking tape idea and will use it for larger tubing, thanks for the hint.

Good tip on the masking tape! I've fabricated both the headers and the rest of the exhaust system on my car. It's a time consuming task, so say the least.....

Originally Posted by Mario428

For headers you may want to think about these parts from Hooker



I have used them for a couple of builds and they work very well.

Holley Performance Miscellaneous Components Products

Not expensive either , 20 to a package

Hooker Headers Alignment Weld Sleeves - JEGS

I do like the masking tape idea and will use it for larger tubing, thanks for the hint.

Yah i found those when i was almost done with the project. Theyd be nice though expecially with a mig welder as i used. They help prevent the slag from building up in the inner dia of the tube when your welding. Thus helping flow.
If i ever do another set of headers, i will be using those.

I do this quite a bit and thought I'd add what I could to help. It it's a striaght pipe like in the pick, you can use two pieces of angle iron on both sides of the pipe. It will make sure the pipe is perfectly striaght. Unfortunely, you also get to see how crooked you cut it.
Also with the curved pieces I like magic markers. I throw the piece up there and draw 2-3 lines acroos the cuts. Take it all off and take it to the bench and line 'em back up. Hope it helps.

When I did my exhaust, I used some of the 2.5" slip fit adapters from the auto parts store...but I cut them into 1" collars...no slag in the pipe...no reduction of inside diameter...easy to mock up...just tack one side...then slip the other pipe in the collar...get it the way you want it...then tack it...then pull the whole assembly down and weld it all...

take a die grinder and make a window in the clamp.

To true up the cut pipe use a belt sander. After every cut true up the tube end so that each point where you need to weld is nice and tight. You'll have a much easier time welding the pipes with out getting slag on the inside.