Altering header reducer
Maybe it's just the worrier in me, but I thought I'd run this by the experts out there: Because of a slight clearance issue, one of my reducers for my new headers needs a modification. If you see the attached pictures, you'll see how I had to cut the reducer back, and put in a new piece of pipe so the whole thing drops down slightly. It hasn't been welded yet.
My concern is with the new 'lip' inside the reducer (see 2nd pic). I intend to flatten it more against the inside of the reducer for a more aerodynamic fit. But there will still be a lip there. Maybe it's my active imagination, but I'm afraid the resistance of this lip could cause it to get much hotter than it should, considering how close it is to the output of the headers. In my mind I see this as a glowing red hot ring.
Am I being ridiculous? Obviously you want everything to be as smooth as possible for good flow, but my concern is making something that will fail.
Grind it as smooth as you can
Followup a year later
Looking through my old posts, I found this one and thought I would make a followup comment, in case anyone has the same question as I did.
After running these headers for a year, apparently my concerns were ill founded. I've had no issues with that inner pipe. I guess I worry about things too much.
Just wanted to put that info out there in case someone with the same type of question comes by this post.
I have Sanderson block huggers on my car's engine. Supposedly they are a premium header - but you sure wouldn't think so if you had seen the welds inside the collector and ports. Between short pieces of stuck on MIG wire, weld boogers, runners that were necked down from cutting them with a pipe cutter and sloppy length fitting, it took me several hours each with a die grinder to make them decent. What you are doing once your welds are smooth will have absolutely no affect on temps.
Oh and mine - they are the reason I would never buy them 'factory coated' but send them out to Jet-Hot after your inspection and clean up
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