At the Deli Counter

The other day I was waiting at the deli counter for my turn.  As I watched the people behind the counter rhythmically slice the meats and cheeses, my mind wandered back to the exhaust alignment problem I have with the cobra.  Then it hit me!  I had to slice some metal off the header flange to change the angle as it leaves the engine.  Not much would have to be removed since a small change at the engine end would be greatly magnified at the other end of a 24 inch pipe.  I left without even ordering my roast beef and went straight for the calculator when I got home.  Yep, by removing 0.1 inch at the bottom of the flange and have it taper to zero at the top should do it.

Now, who could do something like that?  A machine shop would have the tools but could they hold an exhaust header precisely enough for this to work?

To give you an idea of what I'm talking about, above is a picture of an exhaust header standing on end.  I need it to tilt to the right by another inch and plan to do it by shaving some metal off the piece at the bottom.  But for it to work, I have to shave 0.1 inch along the right edge and nothing along the left edge.  That way it will tilt more to the right.  And just as importantly, it all has to be done very evenly along the whole length so the exhaust doesn't leak.  I know, it's complicated, but keep reading.

After searching around for machine shops, I got another crazy idea -- I'd do it myself.  I just had this sickening feeling that I'd run around all day trying to find someone who would try this and then I'd worry to death whether they'd be able to do it right.  Not mention what they'd charge for this service.  These headers were expensive so if they were going to get ruined, I figured I should be the one to do it!  And anyone who knows me knows that I like to do things myself.

I realized the plan actually is based on the deli slicer.  It can make very precise thin slices time after time.  I needed to make an industrial deli slicer and here it is.

I made a sliding table that will run past my belt sander (instead of a blade).  The header is propped-up at a precise angle so it removes material from the upward facing edge.

Maybe this video will make it all clear.

Here's one more picture that I took part way through the process.  You can see that material is being removed from the top and I'm working my way down the face with each pass.

As the video showed, it all worked.  Now, I think I'll put on the windshield.