As I read somewhere here at locostbuilders OEM ZX9R E/F headers aren't easy to weld (some alloy magnesium or something) - can I use ZX9R C
headers to make my own headers as they look like made from different material (easier to weld - I hope)?
ZX9R headers comparison
Top one are C headers, bottom are E/F headers...
They have longer primaries and bigger diameter... but I plan to short it to fit chassis anyway.
Or... should I use something like 2.0 16v Clio Sport headers (or similar) and just weld ZX9R flanges ?
[Edited on 3/4/13 by loony]
I used the "E" headers, the link pipes give a bit more mid range grunt, and ran them as on the bike.
ZX9R-E manifold
Link pipes make something like very short 4-2-(2x2)-1 headers 
That's why I was thinking about car headers too - like Fiat HGT/Alfa 2.0 16V headers which are 4-2-1...
I have to stay over floor level because of ground clearance need (terrible polish roads)
[Edited on 3/4/13 by loony]
quote:
Originally posted by loony
Link pipes make something like very short 4-2-(2x2)-1 headers
That's why I was thinking about car headers too - like Fiat HGT/Alfa 2.0 16V headers which are 4-2-1...
I have to stay over floor lever because of ground clearance need (terrible polish roads)
[Edited on 3/4/13 by loony]
Try and keep your primary lengths and diameter as close to the origional manifold as possible. Otherwise you are in danger of losing huge amounts of
power. When my primaries were wrong the engine would only produce 107bhp. When I replaced the manifold for tuned lengths it produced 141 bhp.
[Edited on 3/4/13 by wylliezx9r]
The C model exhaust that I bought seems to weld like titanium, I know that the standard end can has titanium marked on it and it is indeed TI, so my
thoughts are that the whole system is. When I was cutting up my headers and trying to weld them, they were cracking all over the place. Give it a go
but I don't think you will get a good weld on those headers.
Dave
The port sizes are different on the C and E heads. The E is slightly larger.
I had a new header made. The C series port flanges were cut off the old manifold and new stainless tubes welded to them. Here's the crucial bit
: the primary tube lengths were measured and the new tubes cut to the same dimension. These were then bent and worked to fit the car and 4-1
collector. The standard can was used initially but quickly replaced by an IXIL aluminium one.
Fitted to an E series motor with jetted C series carbs it made 147BHP on the rolling road. The cross linked tubes were not fitted due to me being
tight - seems to go OK.
I found something interesting - they are ZX9R headers, but... aftermarket 4-2-1 ?
Unknown ZX9R headers
Unknown ZX9R headers
Unknown ZX9R headers
They have welded flanges, so maybe they are stainless 
Worth a try (about 30GBP) ? If it's "weldable" I can use pipes etc and just
model it to fit my roadster...
Or should I give it up and make my own SS flanges and headers ?
If so - can I make one big flange (like in car engines) and cut it for separate flanges just before final install ?
I have OEM "F" headers with my engine package, so I can measure what I need...
It's still cheaper to make one proper headers than something to work for now and second better headers later...
quote:
Originally posted by ginger ninja
The port sizes are different on the C and E heads. The E is slightly larger.
I had a new header made. The C series port flanges were cut off the old manifold and new stainless tubes welded to them. Here's the crucial bit : the primary tube lengths were measured and the new tubes cut to the same dimension. These were then bent and worked to fit the car and 4-1 collector. The standard can was used initially but quickly replaced by an IXIL aluminium one.
Fitted to an E series motor with jetted C series carbs it made 147BHP on the rolling road. The cross linked tubes were not fitted due to me being tight - seems to go OK.