Torque Monster Headers Revival

[97Sandbox]

Some may know that I resurrected a set of rusted Torque Monsters which I now have on my Mounty. They had rust holes at in the area where the primaries all come together and merge into the collector, so I set out to fix that.

The TMHs did not initially look that bad, but after pressurizing the headers (using tape and a shop vac in the blow configuration) and spraying soapy water around the collectors, I realized there were a lot of holes. So I carefully hacksawed off the collectors, and media blasted off the rust.

Then I sloppily MIG welded up the holes.

And ground everything smooth again.

Then I had a coworker nicely TIG weld the collectors back on for me. Since I worked at a big plating shop at the time, I was able to get them electroless nickel plated and clear ceramic coated.

All of that worked great! But I no longer work at the plating shop (great for me, but I do miss getting parts plated). I stumbled upon another set of rusted out TMHs last weekend, and now I'm going to try to do another revival, but with more DIY means.

 

[97Sandbox]

Here's the set I scored at my local salvage yard:

At first glance, they look good -- don't be fooled. The #2 primary has a big hole at the head flange and the #3 has an even bigger hole where there was no coating between the #3 and #4 primaries.

There's so much rust down in the merge area on both headers it's hard to tell how many pinholes there may be.

My plan to start is to cut the collectors off and remove the #4 primary. Then I can start stripping the rust with phosphoric acid and figure out what needs patched. I wish I had access to a sandblaster, but I don't anymore.

 

[410Fortune]

Harbor freight cheapo media
Blasters

Good Score even with the rust

I hope mine hold up better then that they have been on my truck 20 years now!

 

[97Sandbox]

I think the way each set of these headers rusts is really dependent on how well they were coated. Due to the complex shape, these headers are not easy to spray coat nor are they condusive to electroplating (the primaries all "shield" each other as they go into the collector). These new-to-me headers are rusted in different ways from the last set I did. You can tell in the picture above it looks like no coating was ever applied between the #3 and #4 primaries -- I'm sure that's why it rusted through there.

But yes, a rusty set is much better than no set! I was considering trying to cobble together a new set by chopping up my first DIY headers and some old fox body headers, but repairing these will be much less work.

 

[Turdle]

Blasting cabinets ain't cheap, but if you get a good skatblast cabinet, and hepa blast vacuum setup ( trust me) , and, 5-7 HP compressor you'll be able to do most items. Coalescser filter, and, toilet paper filter for air into cabinet.
Later you'll want the vortex media reclaimer. It'll save money in the long run.

 

[97Sandbox]

Headers are officially dissected.

Cutting off collectors is necessary to get a welder into where the rust holes are.

Removing the #4 primary was tricky, but the deed is done now.

I figured as much as I'll be welding on these, I may as well do the two-piece driver's side delete.

It'll just be sleeved and welded all around -- no more bolted flanges or gasket.

 

[97Sandbox]

Got my headers back from the blaster today! They look good. I also picked up a section of bent 1-1/2" pipe from Speedway last week, so I'm ready to start patching. Once I get on top of some other projects that is.