Expert: Matt Lyons - 2/18/2008

Question
I really don't know who else to ask, but I'm trying to get a little more performance out of an older engine. Performance parts just don't exist for this engine. So, here's my questions: To make a copper head gasket, what kind of copper and what thickness would I need? And, to fabricate a simple intake manifold, what metal and thickness would work? I'm leaning toward aluminum, since that would be easier to work with. Also, what can a simple set of headers be made out of? I appriciate any and all help. Thank You!

Answer
I would check out the makers of copper gaskets like Milodon and others to see if you can purchase a blank sheet of material. They use dead soft copper. To fab an intake I would make the flanges from 6061 and then use round tube hammer formed to match the ports. For headers, check out headers by ED. He has random bend kits that you can fab your own headers from. He calls them bend mistakes.