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Buy a pace setter 2.0 n/t header and cut the flange off it. Find 1.75 or 1.5 exhaust pipe, plasma cutter, and a 1.8 cast manifold. Cut the flange out extend the pipes 1 or 2 inches, please use the 1.8 cast for reference and weld up. I did my own this way and coated it. Works great, you can also weld nuts on it like I did to cover it of the stock heat shield to get the stock look.


Restoring a 90 eclipse 1.8 34k zero rust just dry rot from AZ
 

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Discussion Starter #2
Re: 1.8 header.....soulution

Buy a pace setter 2.0 n/t header and cut the flange off it. Then find some 1.75 inch or 1.5 inch exhaust pipe, plasma cutter, and a 1.8 cast manifold. Then cut the 2.0 flange off, extend the pipes 1 or 2 inches...please use the 1.8 cast manifold for reference. Then weld up the pipes. I did my own this way and coated it works great. U can also weld nuts on it like I did to cover with the stock heat shield to get the stock look. {edited}:D:dunno:


Restoring a 1990 eclipse 1.8 34k miles Zero rust! Just dry rot from AZ!
I personally want to apologize to the site community for my lack of reading rule # 7 in this thread. There for in the future I will obey this rule to the fullest Extent.
 

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Re: 1.8 header.....soulution

There has been several people attemting this. It's just not easy to weld cast iron lol. The manifold isn't one of the biggest restrictions since it's a dual runner design it actually with minor porting is efficient enough for a mildy strong 4g37. I would rather find the 2nd gen tubular manifold and have a steel flange cut then welded up. How's it working out for you?

Loki, jeez christ man.... I thought it snowed for the last time! ;)
 

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Re: 1.8 header.....soulution

I'm sorry I didn't declare that the aftermarket 2.0 n/t header is a steel header and that it was used and probably will work better since it has already been expanded and contracted from exhaust heat (broke in).That being said you will have to get 1/4'' thick steel plate 24" x 6" piece should do just fine to cut the flange out of. Use a 1.125"-2.25 pipe expander to shape the pipes on the 2.0 header because they are oval. Your right GTA cast iron is very hard to weld, it is possible, but very nasty and time consuming i don't recommend that process. I used the 1.8 manifold to make the flange. I did not cut the stock 1.8 manifold at all. I laid it on the steel plate and then took a sharpie and drew the outline and bolt holes. I then cut the outline with a plasma cutter. I also recommend getting and gasket for bolt pattern and port reference. I used the gasket to drill the bolt pattern holes. I used duct tape to hold the gasket to the new flange. You should cut the port holes on the gasket to match the port hole on your cylinder head and then match your header flange. But to make less work for you (the fabricator) wait until the header is completely welded and mocked up and ready before you match your exhaust ports. Because you may have to cut and re-weld. I didn't and i had to re grind the ports.

Parts needed:
1. 1.8 stock exhaust manifold
2. 1.8 stock exhaust manifold gasket.
3. 2.0 non turbo header

Tools needed:
1. Air cut off wheel or equivalent
2. Pipe expander 1.125" expanding to 2.25"
3. Mig welder.
4. Plasma cutter or a machine shop to cut flange.
5. 1/2" power drill with 5 or more new bits for bolt pattern.
6. Angle grinder with finishing wheel.
7. Dremel tool for porting and weld finishing.
8. carbide bits for porting.
 

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Re: 1.8 header.....soulution

Good job man! Keep us proud!
 

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Re: 1.8 header.....soulution

If only i could weld. Is that 2.0 pacesetter a 4-1 or 4-2-1 design? I've been thinking about doing the same thing but with one of those ebay b series 4-1 headers.
 

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Re: 1.8 header.....soulution

The bottom flange is the stock 3 bolt........2 into 1 left....2 into 1 right....so I'm think 4-2. I'm going to post pics of it by the weekend.

When you weld it tack-weld it only or warping will result to the point your cutting and re-welding again and again.

I was also thinking of making a production of my own with grant and patent number. I know they are wanted.
 

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Re: 1.8 header.....soulution

If only i could weld. Is that 2.0 pacesetter a 4-1 or 4-2-1 design? I've been thinking about doing the same thing but with one of those ebay b series 4-1 headers.
Justin can weld decently, when you come to paint the car bring it up too and we'll weld it together. BTW did I forget the shaved 2.0 cam gear???
 

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Re: 1.8 header.....soulution

Ha ha yea, its still on the chair outside.

Even tack welding it, i think it would be a good idea to take it to a shop and have them machine the flange flat again once its done.
 

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Re: 1.8 header.....soulution

Hang onto it for me man, I'm gonna ask my neighbor this week when he goes to grab it for me. Is that cool?
 

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That's a good post man, I'm sure a few people would like a header for their 4G37.

And the Pacesetter header for a 4G63N/A is a 4-2-1.
 
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