Ok, i have a small new project (ok maybe large) and those who have made equal length headers before (and had them last a long time) i need a little advice.
flanges? mild or stainless? weld stainless pipe to a mild flange ok or a total no no?
weld els? good place to get them?
flanges? good place to get them? specifically DOHC chrysler head, pre 2001. IE neon. oval port not the SRT squareish port.
divided T4 inlet flange?
can mild steel (sch 10 or 40 most likely) if the assembly/turbo is supported and allowed to move around a bit with heim joint bracketry but the weight is supported?
thanks guys.
Brian
I like mild flanges, they warp less than stainless flanges and also expand less. Ive seen guys weld stainless pipe to mild flanges with no problems too. If you wanna use schedule 40 mild steel you can get weld els at ERB co but if you wanna use stainless you should prolly go to mcmaster carr or somthing. One place i know that has good flanges is BMC racing, good quality for the money, they just ship slow. I think it was bmcrace.com or somthing… Divided tang T4 flanges are great, support good power with better spool than a non divided housing, youll just have to join cyls 1-4 and 2-3 into each side of the flange. What exactly do you want the manifold to do? Be flexible or just support the weight of the turbo etc on the manifold? Schedule 40 mild steel will support the weight and shouldnt crack if you put it together correctly, minimal if any bracing required. I wouldnt go smaller than schedule 40 mild, if you wanna go schedule 10 you should def go stainless, but youd have to brace the snot out of it. 1.5" id should be fine. If you go mild steel, just paint it with hi temp bbq paint to make it look presentable.
www.jgstools.com has a bunch of diy turbo stuff check them out.
Brian,
I got my sched 40 weld els from a place on Lyell, near Mt. Read. Ill see if I can find the name / number etc for you tonight.
I have no supports on my manifold, and have yet to see any cracks etc. However, it doesnt exactly have a ton of miles on it. Maybee 5-7k.
I would just do it all in mild steel. But thats just me. I cant justify the cost of ss, and Im gonna guess you cant either ;).
EDIT: I can probably Mig or Tig this up for you if you need. Dep on when etc.
Dan
thanks guys. i have this same thread on another board and you guys posted pretty much the same links. yeah i know about JGS. thanks though.
yeah dan, if i only spent 150 on a turbo (no not china), im gonna lean towards mild steel. 
yeah i can do all the measuring and stuff here and tack it together and then some sat or something i can bring it over and we can go to town.
Brian