Why do NLR headers cost more?

[NLRsystems]

SO I figured Id give you the insight of why the NLR turbo manifolds costs more than the other units on the market.
First some insight on the materials used. All material is 304 stainless steel. The tubes are .109 thousand thick .
Working with this material in comparison to the .065 wall material used in other headers is very different. This thicker material takes alot longer to cut as it is very thick and work hardens with the heat generated by the saw. So you constantly have to cool it with cutting oil or your screwed.

Once you have cut the material you then have to prep all the edges with a v groove before you begin to fit them. Once all the parts have been cut and prepped with beveled edges you are ready to begin.

The main flange is water cut 304 stainless steel. This is cleaned and edges are prepped.


Compare the thickness of our flange to others. It will not bend which makes it difficult to get bolts out after use.


here is the fixture I use to build the headers. Extremely thick and very adjustable. It comes apart in parts so I can remove the fixture to weld the header without taking a chance on anything moving.


Next I have to make the main spigots. They are made from 304 stainless as well and are very heavy duty. They are undersized by just enough to slip into the head perfectly. Each one is hand made by me on a lathe to an exact fit!




The thickness of the spigot is very important when it comes to sealing . Often overlooked by others.


Next we get ready to install the spigots and weld em


The spigots get pressed into the flange..yep you heard me pressed!


The they are welded into place

[NLRsystems]

Once welded there is always movement of the main flange from the heat. So its put on the table and made flat again by seam welding with clamps in certain areas. When finished it is perfectly flat. This takes alot of time but its important its done right or it will never fit.



Once this is finished it can be placed in the fixture and bolted down


The turbine inlet flange is 304 stainless steel and is a very thick part. The flange is made with 2 1 inch holes as I hand port this 1/2 piece .



Next step is welding all the pre prepped parts and set them in the fixture.


Once these parts are in its time to make the connection pipes. I have a pattern I made out of a stainless pipe that slips over the material. Trace and plasma cut and grind, sand, fit and clean and then fit into place. Once this is done it needs to be traced onto the two main runners on cylinder 2 and 3. These are then removed and plasma cut, grind, sand and fit and cleaned. Install back into the fixture, fit the connection tubes and weld.


Once welded they need to be removed to hand port the inside of the pipes. This is more of a shaping as everything is back purged so there is no slag or anything in the header. Once finished with this it can be placed back into the fixture and cylinder 1 can be finally welded to 2 and 4 to 3.

Final product ready to come out of the fixture. Flange has been welded.

[NLRsystems]

Now for the fun part. Hand port the outlet into the turbo. This is a very long process but just like head porting its an art and critical to how the overall product works. This process takes about 3 hours.






For the turbine housing we move. Most manufactures just weld the pipe onto the outside of the turbine housing we do not.
First we bore a hole into the housing. The hit it with a drum sander to open it up to the exact size of our pipe.


Next we cut our pipe to be inserted. In order to make this part extremely strong we make the hole large enough so the pipe can be inserted all the way thru into the turbine housing. Once we weld the outside which is done with expensive inconel( higher nickel content) filler rod rather than 308 rod we grind out the inside to contour with the turbine housing. Once this is done it is welded on the inside as well. You now have a wastegate pipe that is not just an part welded on that can crack and fail but a integral part of the turbine housing.



So there ya have it. Yes we have a long pain in the butt process to make these parts but it is the only way to deliver a completely bullet proof and the highest quality , best performing part to our customers. In the end I charge about 500 more for my turbo manifolds than the rest but I feel it is superior in every aspect. It will not crack, bend , break, fall off, leak or cause you grief trying to remove. You will not have to brace it, repair it or fix anything which I believe makes it worth the money.

seb

[P.Cooper]

wow ! Nice illustration also.

[Big Boost]

Sure is nice work.

[onedownfiveup]

Sexy as hell!

Your headers are in my mind when I make the purchase next year!

[sideways]

Next time somebody balks at the price......
I like how you make the pipe part of the housing






And after they tell you how awesome it is you can say "We Try" or is that just for TV?:bumping:

[Goldenchild]

$500 in the end difference is worth the performance and reliablity of the product.Nice Job Seb...

[#1bigchief]

So again why does it cost so much? Just kidding Seb, nice work. Maybe one day I'll be able to afford your work.

Fred

[punksrfr]

This kind of attention to detail is the reason I respect NLR so much! Very nice work Seb. If I ever purchase a system instead of building my own, your are the man I will be calling. Thank you for the write up.

[Vanilla Gorilla]

[NLRsystems]

[slammedzx9]

nice work Seb

[TunerRacer]

Nice, now instead of me explaining this over and over i can shoot'em over to this thread. Thanks Seb!!!


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[Frank Adams]

Nice, now instead of me explaining this over and over i can shoot'em over to this thread. Thanks Seb!!!


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I haven't checked if he has yet, but he can use the Thread Tools option and copy the thread into either of his forums in the midway.