Merge Collector Fabrication

Tackling a new DIY project can be a scary task; especially when it’s on something as important as your car and merge collector fabrication. There’s a definite sense of achievement, however, when you manage to pull it off and that’s exactly why we’re going to show you one of the most common steps needed when it comes to making a modification to the engine of a car: fabrication of merge collectors. If you’re looking to make something like race headers, which are an important part then you definitely need to have merge collectors.

We’ll go over everything you could think of possibly needing to ensure that your journey goes smooth, including challenges to be aware of as the project progresses, a few of our own tips that we’ve found have helped us, and we’ll touch on those more precise details that tend to be left out when it comes to fabricating.

What is Fabricating?

Fabricating doesn’t mean anything technical or fancy. It is the act of manufacturing something, or constructing it, with only the materials available to you in some form (whether complete, or need to be modified by yourself beforehand).

You can purchase collectors, of course. There is a wide range available, made from different grades of material but they can be expensive – and there’s nothing quite like the satisfaction of a job well done and a slightly heavier wallet, either. Making your own with the right instructions doesn’t have to be difficult, either, and there are plenty of good guides that can walk you through it step by step.

The Materials

Car engines get hot. That isn’t a myth, or a fact that doesn’t have evidence to back it up. When a car has been in high use, it’s not abnormal for the exhaust pipe to feel a little warm (read: hot!). This means that the material you pick needs to be able to handle high temperatures without sacrificing any of the quality you’re expecting.

It’s recommended to pick stainless steel. It comes in many different grades. The recommended two are either 304 grade, or 321 grade. To give you an idea, 321 grade is also classed as ‘aircraft grade’ which makes 304 the common choice for this sort of product – it’s not too expensive, and thermal conductivity is kept to a low, meaning you don’t need to go to other lengths to ensure that your exhaust energy isn’t escaping from the pipe. You want it to stay in there!

Another benefit of stainless steel is that it doesn’t rust, unlike other metals, and gives you a much nicer and cleaner finish. While cosmetics aren’t always the important part of fabrication and the point is to have a working item at the end, it’s still always a benefit to have something that works as described and looks good to boot.

Sometimes, it’s queried why aluminium isn’t a usable material, and this is easily explained. While aluminium is cheaper and lighter, it’s also not very strong when … Read More