Icengineworks 1-5/8 inch Header Full Fabrication System

Go from concept to finished header faster, with less waste and fewer fit-up problems.
The Icengineworks Complete Exhaust Header Fabrication System is designed to help fabricators model, cut, and weld custom headers and turbo manifolds with greater speed and accuracy. This complete kit includes modeling blocks, tube cutting jigs, and welding clamps so you can move from mock-up to finished metal with a cleaner, more repeatable process.

The snap-together blocks let you quickly build header primaries and test routing before cutting metal. Once your design is finalized, the included cutting board, alignment blocks, and tack-welding clamps help you duplicate the layout in steel tubing with better accuracy and less trial and error.

Why Fabricators Choose This System

• Design Headers Faster: Quickly lay out custom headers and turbo manifolds.
• Reduce Waste: Cut down on trial-and-error mistakes, scrap, and rework.
• Easy Mock-Up: Blocks simply snap together to model each tube section.
• Accurate Transfer to Metal: Markings and index points make duplication easier.
• Better Fit-Up for Welding: Clamps help preview, clock, and align tube sections before tack welding.

How It Works

1. Model the Header Layout:
Straight and curved blocks snap together to simulate header primaries and manifold routing. Each block represents a 1" arc length of tubing, making it easy to visualize and refine your design.

2. Transfer the Design to Steel:
Use the included cutting board and alignment blocks to duplicate the plastic mock-up in prebent U-bends and J-bends. The aluminum cutting board is designed to run against the fence on a vertical band saw for accurate, repeatable cuts.

3. Align and Tack Weld:
The included welding clamps hold the cut tubing in position so you can preview, adjust, and clock each piece before tack welding. This reduces time-consuming cut-and-reweld corrections.

What’s Included

• (60) Straight Blocks, 1625-00
• (60) 2" Radius Blocks, 1625-20
• (60) 3" Radius Blocks, 1625-30
• (60) 4" Radius Blocks, 1625-40
• (8) Block Adapters, 1625BA
• Universal Aluminum Cutting Board, PIV1000
• Cutting Spacers for 2", 3", and 4" CLR
• 4-Piece Tack-Welding Clamp Kit, 1625TTWCS
• Manual
• Control Sheet Pad
• Plastic Case

Key Features

• Design and layout headers quickly and easily
• Reduces time and material waste
• Blocks simply snap together
• Includes Pro Modeling Kit, plus clamps and cutting jig
• Blocks of different sizes can be connected to simulate stepped headers
• Built-in markings and index points simplify the move from plastic to metal

Ideal For

• Custom exhaust header fabrication
• Turbo manifold design
• Prototype header routing
• Reducing fabrication time and fit-up errors

Frequently Asked Questions

What can I build with this system?
This kit is designed for custom exhaust headers and turbo manifolds.

Do the blocks represent real tube length?
Yes. Each block represents a 1" arc length of tubing, making layout and duplication easier.

Can I model stepped headers?
Yes. Blocks of different sizes can be connected to simulate stepped header designs.

How does the cutting board help?
It helps guide tubing across a vertical band saw for accurate cuts when used with the included alignment blocks.

Why are the welding clamps useful?
They let you preview, align, and clock tube sections before tack welding, reducing costly adjustments later.