design and modeling
The most important step in our system, STAGE I allows builders using our patented plastic blocks to quickly generate the tubular shapes and geometry required to test fitment, ease of fabrication and even set budgets for any project. The only requirements are that the engine is fitted in place with flanges and starter tubes and that exhaust collectors, or Collector Dummies are firmly secured in their final positon in the engine bay. Sold in sets per SERIES (tubing OD specific).
With the information from STAGE I, STAGE II provides a fast and accurate way to cut the required metal sections out of standard U-bends and J-bends. STAGE II tools work with most vertical band saws. They include a universal cutting plate and a set of OD specific or SERIES-specific machined HDPE cutting spacers to hold the U-bends or J-bends. Sold individually or in packages.
assembly and welding
After the individual metal sections for the tubular exhaust header project are cut, builders move to STAGE III: Assembly and Welding. STAGE III utilizes one of the most innovative products to hit the fabrication industry in decades: the patented icengineworks™ stainless steel tack-welding clamps.
These clamps provide an amazingly quick and exact way to firmly hold multi-sectional tubular assemblies together. Proper relative rotation at each joint is easily and minutely adjusted until the entire assembly becomes a solid and faithful recreation of the original plastic block model. They provide safe and endless opportunities to verifiy fitment for clearance, accuracy and exact alignment with the receiving tube ends at the head flange, exhaust collector or Collector Dummy prior to tack-welding the assembly. Sold in sets of 4 and 8.