How To: Making a Mac Header

Jeff Clark

Jeff Clark

#1
#1
I haven't posted any form of project or a how to thread in some time so I decided to make a thread on a new part I will be making soon.

I will go through all the steps in real time so it might get a little boring over the next couple weeks but it is what I have to go through in making a part.

No, there will be no royalties because you read this thread...

First thing is deciding on what parts to make and if it is worth while, on this part I need a few and so does a unnamed friend who will be helping with this project, and I know it is probably good for a solid 20 parts sold quick then one here and there.

My new part will be a McCulloch Header they are cool looking rare and well just cool looking...

This was my first step playing the auction game to get a doner part

Vintage Kart McCulloch Bugle Exhaust Racing Go Cart | eBay
 
Jeff Clark

Jeff Clark

#3
#3
After receiving the doner part and inspecting it, it will need a good cleaning that's for sure!! this old fuel mix oil on here is really baked on. The doner is a bit beat and hacked on but that's perfect to me I didn't have to pay top dollar for it and it will be turned into a pattern board so who cares.

 
Jeff Clark

Jeff Clark

#4
#4
When I was looking at it for sale on ebay I noticed the home built bracket that was screwed to the back, what a pain that was getting it off with the baked on oil inside trying to hold the bolt with a wrench sucked! But what I didn't know is that the original part had a raised area just for this? so I have decided on the new part I will ad some material to this area so it can be drilled and tapped and a stud used.




The next step is to try and clean it some so I threw it in the Vibratory and it is viben away now.
 
Jeff Clark

Jeff Clark

#6
#6
another view, On the back side you can still see the part line from the pattern board when the original part was made.

I will clean this part up a lot, it is quite a crude casting not much time was spent making the original board.

Next step is to send the part out and have it cut in half with a EDM, with the holiday weekend it will be a solid week before we see more.



Original part line

 
TANKSAREUS

TANKSAREUS

#9
#9
Time for the stupid questions - Sorry

Wht EDM wire cut the part in half? Would a bandsaw not work, or does it remove to much material?

Thanks

Ps the only reason I ask all the questions is because I admire your work and take an interest in what you do :thumbsup:
 
Jeff Clark

Jeff Clark

#10
#10
TANKSAREUS said:
Time for the stupid questions - Sorry

Wht EDM wire cut the part in half? Would a bandsaw not work, or does it remove to much material?

Thanks

Ps the only reason I ask all the questions is because I admire your work and take an interest in what you do :thumbsup:
Click to expand...
Your correct the EDM will remove .008 from the part and band saw would be very cude and .075-.090 ish I would guess. The part is boxed now with some goodies for my buddy to work with, I will probably cut the board with some pics this week but the header will be a week out I assume we will all see keeping the thread in real time.
 
Jeff Clark

Jeff Clark

#13
#13
Jeff Clark

Jeff Clark

#15
#15
This is what's going on with the project today, And I want to say Thanks!! it is sure nice to have friends to lend a helping hand with stuff like this :thumbsup:

The header set up in the EDM, it was bolted to a plate as a fixture to hold it in place while it is being cut. This is a slow process but does such a nice job!





 
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