Thank You guys...
ORIGINAL: impactiq
<snip>1.On the fuse top style headers from Mac, the pipe is cut on a angle where it meets the header flange. The pipe itself would hang over the header flange at the bottom and would be filled in with "weld" to fill the gap. On mine the crack would start at the joint in one of the corners where the pipe over hanged the header flange and work its way around do to a lack of "weld" in these areas.<snip>
Yeah..I think that is what I was noticing as "crude" workmanship...I personally think that is a good example of "How Not to" Fabricate a Header...A nice source for locked up stress...Just my opinion...
I have a TIG Welder with High Frequency capability...I love when I get the chance to dust it off and play around...It's just me and Aluminum don't seem to "Gee Haw" all that well together...Gimmie some .035 4130 and I'll have a Big Time!! But mean ole Mr. Aluminum doesn't like me..he he (I don't like him either...lol)
It doesn't help that my Miller EconoTig's minimum is 20Amps which is a bit too hot for .035 Aluminum...I just have to learn to "Pedal It"..(Kinda like John Force when he starts spinnin'..he he)...A buddy of mine also mentioned I should try Pre Heating and that may make my life easier...So I'll give that a shot too...
I'll probably monkey around with these...Just too see how big of a mess I can make...lol...I got 3 or 4 more headers that are trashed also..I have some 6061 tubing laying around...I think I'll have a header fixin' and fabricatin' day this weekend...Should be Fun!!
So..I'll have lots of Patience...Pre Heat..Back Up...Pedal it...And Drink Lots Of Beer...(My 5 Keys to Successful TIG Welding..he he)
Have Fun...
Chuck