icengineworks offers precision exhaust header modeling systems that allow you to build headers in hours as opposed to days or weeks. Their innovation in the fabrication industry is second to none and their products are sure to be the future of fabrication.
Stage I: Design & Modeling
Regardless of engine type, engine builders are presented with a challenging spatial problem when designing a tubular exhaust header system. Multiple complex branches made of arbitrary straight and bent sections of preset outside diameters [ODs] have to be arranged efficiently to create a compact package that can easily be fabricated. But determining the best layout among all the possible pathway combinations is a challenge. If we define the solution to this problem by devising a method to explore as many combinations as possible and zeroing in on the most feasible, at minimal cost and in the shortest period of time, a strategy to tackle it can then be drawn.
By breaking up the overall solution to this problem into a finite number of partial solutions that can be solved one by one, the design problem is dramatically simplified. icengineworks has successfully turned these partial solutions into modular, interconnecting straight and curved plastic modeling elements or blocks of certain OD and length that faithfully represent round metal sections in an exhaust header design. Engine builders can now design precision exhaust header modeling systems in 3D by hand.
The system requires the user to have exhaust header flanges (not included) with stubs installed in the engine. In addition, the collectors must be supported in their tentative location. When assembled, these blocks form strings that serve as 3D models of actual primary runners. By carefully choosing and positioning each block added to an assembly while keeping track of the length, the designer quickly discovers the most optimum pathway between the header flange and the collector. If interferences are found along the way, the blocks are simply rearranged. This new design capacity to do and undo freely, opens up an unprecedented opportunity to quickly create more efficient, tighter and seemingly more complex designs. And the savings, due to the elimination of unnecessary labor and wasted materials, add up right away.
It is now possible to design, revise, correct and rearrange, almost endlessly, at no extra cost, without waste, any design until every aspect fits and feels right. Specific design intent can easily be introduced such as minimum number of sections per runner, plan for location of welds, or steps, design with CNC bending for production in mind, etc. When you are ready to fabricate in metal, you will find that all the information required to build the design is already at your fingertips.
Stage II: Tube Cutting
The fabrication process starts by recording your design information, section by section, on the provided Metal Control Sheets. These become the blueprints and shopping list for your specific design. They are also the way to do repeats later on of the same design. Then, each section according to the list is cut by creating and placing an equivalent section made of blocks, on the PIV1000 and around a CLR-matching Cutting Spacer. The spacer is spun until the end of the plastic section gets aligned with the band saw blade. Then, the spacer is tightened to fix its location and the plastic section is replaced with the actual metal U-bend.
By adjusting the band saw's rip fence so that the blade aims at the center of the pivot on the aluminum table, the U-bend gets cut by gently pushing the Pivoting Table attachment into the cutting blade.
Use J-bends or U-bends to turn designs modeled with plastic blocks into a full metal header thanks to the fabricating tools icengineworks has developed to complement the system. Partial angle bends are no longer necessary, which reduces required metal inventory. By utilizing precision U-bend or J-bends of matching CLR, it is very easy to transfer your design model into metal, section by section. Using a vertical band saw [10"+ throat capacity] for metal cutting, the icengineworks aluminum Pivoting Table attachment [PIV1000] and the HDPE Tube Cutting Spacers simplify the task of accurately cutting bent sections.
Stage III: Assembly & Welding
This process yields all the parts required according to the Control Sheet recipe, to assemble each of the modeled sections, with each section labeled with information such as the cylinder they correspond to, the section number in that runner, and its orientation, for example indicating which ends point downstream and their witness lines.
One at a time, and for each runner, replace each model block sections with their metal version by aligning their witness lines and tack-weld. Continue until the entire design is completed.
Then, use the innovative tack welding clamps as extra sets of precise hands that don't get burned or tired, while keeping a firm hold of the tubular sections to be welded.
We are proud to carry icengineworks products here at Verocious Motorsports! If there is an icengineworks product that you wish to purchase that you do not see on our website don't hesitate to call us at 877-VMS-1320 and one of our friendly staff will help you secure that product.