Finally - A GROUP BUY HEADER!!

The time has finally arrived. I have extensively searched and researched and have found someone to make us a real header. In my lair I have already dimensioned the flange and am currently drafting the flange digitally. This is no longer a dream to this forum, this is happening.
The header will fit my 08 Aveo 5, with no AC. Unfortunately, I am unable to be sure of the fitment with AC,but if you choose to buy, you may have to reroute AC lines, components, or remove the entire system. I can't make guarentees other than flange and support fitment. There are no other aftermarket obstructions in my engine bay and I hope to make this a bolt on part for you all.
The only option for this header is stainless steel. This is non negotiable. If you can't pay, you can't play, sorry. Which brings me to the bottom line, money. This is not cheap. I'm not even paying my time in this, I am just passing that on through you all. At this stage I do not have a definite number, but I got a quote of 500-600$ US. This is the absolute best quote by a long shot. My hope is to bring the price down by negotiating a bulk buy.
The design is a long tube, tri-Y. This design will give more low and midrange torque, the place where we can utilize it the most. IT WILL DELETE THE CAT!!! I am going to make the best efforts to allow a test pipe insert so you have options, but that is not 100% definite. I will also be making serious efforts to keep CEL issues away from us.
I will be making some sort of a Pay Pal account payment option when I am closer to pulling the trigger. Like many of you, 600$ is not chump change so I cannot produce an overhead stock for you to purchase.
Any thoughts, comments, or design ideas? Please tell me. I want this as bad as all of you.

Attachment 10737

The formative stages. Once I do a digital draft, you will get a fully dimensioned sketch for reference.

04-06??? any way to modify to fit?

Will it fit on the earlier gen Aveo's (05-08)?

I have a first gen. Correct me if I am wrong but this will go from 04-08. It will fit the E-Tech II, or more specifically by the GM production code, GML91. If I have a large (5+) number of inquiries for the second gen, with the Eco-Tech, I may consider designing one, but it may be a challenge since I don't own a second gen. I want to complete this project first before attempting another, but I will certainly consider it if enough people really want it with cash in hand.

I have the SVP Aveo with a dealer added AC, I will be more than happy to take pictures showing the routing of the AC lines and condenser coil. I am in repairing my front bumper so I will have it off. Not sure if this the right thing for me but I am willing to help design process.

Please do, if I can avoid AC conflics I will.

Any updates on this Stumpy? I think its great you're going ahead with it.

Nothing extra yet. My next 3 moves are to create a digital file of the flange, somehow print or prototype it so I can match it to the gasket, and revise if needed. This may be a back and forth a few times, all of which has to fit into my schedule. I wanted to create this thread well in advance in order to allow others to save up to purchase, add input etc. Especially because this could be a "one shot deal" as far as making headers for this engine. It has the possibility of being the first and last run of good headers special order for the Aveo.

If you want, I can help you make a .dwg or .dxf file of the flange. I'm a mechanical designer and have access to the software. I actually have a scan of an etec exhaust flange. I just need a reference dimension, like the port height so I can scale it properly in the software. Then I can trace it. You can use that file to get it laser or waterjet cut.

Sorry for the delay, the holiday season increases my workload like, whoa.
This is what I have. Theae measurements are not laser line perfect, I was using a Harbor Freight digital caliper on an import made gasket. I took a shot with my phone and I am not resizing it with the intention that you will be able to zoom in and read these measurements. There are some notes and math on it, double or even triple measuring of the seemingly same distances and diameters. It is a diagram more than a blueprint but, hey, who is hanging it on the wall anyways.
Again, forgive the giant image.

Attachment 10796

That should do great. I'll let you know what I come up with.

oh my I am behind on my pictures. need to get those up soon, I have my front taking apart again.

Good news-
I touched base with the fabricator and he was very agreeable to a group buy discount per piece. I told him I was going to supply the flanges to lower the price as well, somewhere closer to the 500$ zone. I also contacted my old machine shop instructor who said he would aid in the machining of the flanges. Prices are still yet to be discussed with him, but hes a really cool guy who is into cars (crosses fingers for a freebie)
Happy new years all! This is the year of the header!

That is great news Stumpy! Very nice work. $500 is very reasonable considering a one off header, or very low qty order.

Alright, I had posted a file, but then I noticed something didn't agree with your measurements. I wanted to double check, so I deleted it. The one dimension that doesn't agree is the distance between the ports. I come up with ~1.58, and you have ~1.395. Thats not a tiny difference. Could you double check?

Attachment 10825

I had promised to get a picture showing the clearance between the header and the AC.
Here it is:
Attachment 10832

Sorry for delays- travel and holidays :)
Good work Daox, I will confirm measurements shortly.
xintersecty- I think we will be in the clear. To keep costs down, it won't be a wild design like a rams head. It will be more like a gentle 90 from the side profile, with the outer ports coming toward the center from a top view. Very much so function and utility.

Okay, you are correct. I measured 1.595 roughly on a gap between all ports. I must have messed up because I was rushing on break at work. Also, if possible, can you make the ports a bit larger in respect to the longer side? Accuracy is good otherwise. ��

Great! Otherwise your measurements and my gasket wouldn't line up! I'll make the ports about 1/16" longer horizontally.

Lol it would not have even matched my own gasket. Maybe I used a poor choice of words on revising ports so I am giving a pic. Also, if you fillet the bolt areas, it will help prevent stress cracking points and help make machining easier. I don't mean to be picky but we have a one time gig on this.
Attachment 10858

Ah, gotcha on the ports.

Yep, the corners will be radiused to match the gasket. The radii are controlled in another part of the model not shown in the sketch. I'll post a picture of it when I have a minute to upload the .dxf file. Good thinking though.

Status update? Once the file is complete I can prototype it for mating comparison!

Its just about done. I'll see if I can't get it finished up today for you.

I had some time over lunch. The attached is a zip files with a dxf and dwg file in them. I opened up the ports vertical distance to 1.18".

Here is a picture of the flange.

Attachment 10906

Have you had a chance to talk with any shops about making the flange?

Hi guys, How is the project going ? i'm in if it will fit 07

Yes it should fit all the E-tech II motors.
sorry for delay, I had a bit of work troubles. I am sending this file out for a prototype sheet metal lazer/water cut. Then I can match it to the gasket. I haven't lost steam, just have been modding other sections of my car.

Hey y'all my old car has some bushing issues, always does when they can't handle the car.. anywho definitely interested in buying this piece, and as with the lowering links, if there aren't enough buyers, I'll buy two and eventually sell the other one to someone else. Remember that old xiaogary thread about the header adding 14hp? Thats significant at this price point. Just my two cents on the header for the etec-ii series motors. A good header is a good way to start.

Quick update on a seemingly dead thread:
First fabricator has dropped off the map. No idea what happened to his shop.
I went through some personal family things (good but required attention).
I have found a local engine builder with a full machine shop. He goes to my church ��. He is willing to machine flanges for me by the piece. He also works closey with a fabricator that is willing to weld this puppy up.
The one thing is that he doesn't work stainless. What does this mean?
While the header won't be "top quality," it will be fully functional and be cheaper for everyone to purchase. I do know of a shop that does the ceramic coating too, if one was hot on that. Stay tuned, this is not over.
Because I now will be working with this machine shop, the future list for custom parts may include:
Rear hub conversion to disc
Front big brake bracket/kit
Adjustable sway bar bracket for VW coils (no more buying adj. endlinks)
Strut tower brace
Rear hatch brace

Its great to hear this isn't dead. :)

I second that thought :) After spending a wack 'o jack on that power steering rack fix I haven't been doing anything to the car in awhile.. but this would be a great way to get back into it. Been off the forum for awhile, its been too fun a summer.

Any update on this? My exhaust header is getting very close to rusting its way off the (whats left of) brackets, the bolts don't even look like bolts anymore just a rusted lump here and there.. flex pipe is snarled from bottom outs, its starting to rattle, tip plug on the end of the flowmaster rusting out.. was thinking if this header does get out in the next months it would be a great reason to redo the entire exhaust with mandrel bends and stainless. May have to do it sooner than later, the exhaust manifold, the o2 sensors, flex pipe, cat, all stock, they should all be replaced.

Hey Daox I might end up having to fab something like this up using a to scale jig of your drawing. Do you have any suggestions about making a jig and starting with a thick piece of aluminum. Would get an estimate of having it made but I'm guessing its probably just too expensive, and better to make or mod.

I'd print out the PDF on paper and then transfer it to metal. You can cut it by hand, but it would take a long time. A drill press and a hole saw can get it done. It will just take a long time.

Alternatively, you can take that DXF file and contact some local laser, plasma cutter, or waterjet manufacturers and see if they can make one for you. Someone could also cut it mostly by hand for a cheaper amount with a plasma cutter or just an oxy torch.

Ok, sounds good I'm way ahead on this, but getting the plan together. I was thinking of getting 'close' to the trace line using an angle grinder and thin disks, and cutting away small rectangles around the perimeter, then then the bigger disks for finishing. And a small drill press and hole saw for the interior. Maybe a pneumatic die grinder might be available too.
Guess three local shops should be called too whether they be laser, plasma cutter, or waterjet to at least get a price point on a one-off, or a two-off.

I am in for a header just keep updates going plz definitely help my aveo after being lowered

Did this ever happen? Or, is anyone aware of a source for a header? Thanks.

As far as I know, nothing ever came of it.

I have an exhaust header for 04 to 09 Aveo
Bought awhile ago never used and sold my Aveo.

$150 will try to add pictures. Header only and has spot for 02 sensor.