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Port matching and Falcon Group 44 headers

To: 6-Pack <6pack@Autox.Team.Net>,
Subject: Port matching and Falcon Group 44 headers
From: Don Malling <dmallin@attglobal.net>
Date: Sat, 13 Nov 2004 09:00:07 -0500
The round tubes on the Falcon Group 44 SS headers are welded to a head 
mounting flange. The head mounting flange has rectangular ports which 
appear to match the exhaust ports in the head. My plan is to port match 
these rectangular flange ports with the head ports.

The question...

I've noticed that the edges of the round pipes infringe on the corners 
of the rectangular flange ports.  That is to say, the diameter of the 
pipes is slightly smaller than the diagonal measure of the rectangular 
flange ports. Based on the size/thickness of the weld that attaches the 
pipes to the flange, and which is on the external side of the pipes, it 
would appear that I could safely file away this small portion of the 
round pipe that infringes on the corners of the rectangular flange 
ports. This is a small infringement, but none-the-less, in the very 
corners, the weld material is visible, so I would have filed through the 
thickness of the pipe and would be filing into the weld at that point.

Should I do this or am I worried about nothing? That is, will doing this 
  provide any noticeable flow improvement for a street engine? It would 
seem to me that even small obstructions would/could lead to a 
significant amount of turbulence, and that it should be done.

Thanks,

Don Malling




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