Burns Catalog 2005xxxxxx.qxd - Visiter le site web de l'utilisateur ...

Due to increasing materials costs, Burns Stainless may impose a surcharge on products at any time without notice 

Contents 

304 Stainless Steel U-bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 

304 Stainless Steel J-bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 

304 Stainless Steel 90º and 15º Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

304 Stainless Steel 45º bends and Straight Tubing . . . . . . . . . . . . . . . . . . . . . . 5 

304 Stainless Oval Tubing, Mandrel Bends and Transitions . . . . . . . . . . . . . . . . 6 

321 Stainless Steel U-bends and 90º Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

321 Stainless Steel Straight tubing, Service Costs . . . . . . . . . . . . . . . . . . . . . . 8 

6061 Aluminum U-bends, 90º Bends, and 45º Bends . . . . . . . . . . . . . . . . . . . . . 9 

6061 Aluminum Straight Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 

Inconel Tubing and Mandrel Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 

Racing Merge Collectors - General Information . . . . . . . . . . . . . . . . . . . . . . . . 12 

Base Merge Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

Double-Slip Turbo Collectors and Splayed Collector Options . . . . . . . . . . . . . 14 

Transitions and Megaphones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

X-Design TM Computer Analysis Service for Racing Exhaust Systems . . . . . . . . 16 

DynoSYS TM and B-TEC TM Adjustable Collectors . . . . . . . . . . . . . . . . . . . . . . . . 17 

X-pipes, Y-pipes and V-Band Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

Flat-band Clamps, Silicone Hose, Hump Hose and Reducers . . . . . . . . . . . . . . 19 

Adel Wiggins Flexible Tube Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

Turbo Inlet, Downpipe and Wastegate Flanges, 3-Bolt Flanges, Head Flanges . 21 

Collector Tabs, O2 Rings, Header Bolts, Solar Flux, and TIG Welding Rod . . . 22 

UltraLight Stainless Motorsports Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

BurnSonic TM DR-1 Lightweight Collector Muffler . . . . . . . . . . . . . . . . . . . . . . . 24 

Stainless Steel, Inconel and Aluminum Technical Articles . . . . . . . . . . . . . 25 - 29 

Reference Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 31 

Race Engine Specification Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

Burns Stainless LLC 949.631.5120 Monday - Friday 7:30 am to 4:30 pm fax 949.631.3184 burnsstainless.com 

1

304 Stainless Steel U-bends Surcharge may apply 

U-Bends 304 Stainless - 16 gage (.065) 

O. D. Part Number Legs Wt. lbs Each 

3/4 UB-075-20-16-304 6 x 6 0.72 $ 22.46 

1 UB-100-25-16-304 6 x 6 1.07 $ 25.00 

1 1/4 UB-125-20-16-304 6 x 6 1.25 $ 28.01 

1 3/8 UB-138-25-16-304 6 x 6 1.50 $ 29.27 

1 1/2 UB-150-25-16-304 6 x 6 1.65 $ 29.17 

1 1/2 UB-150-40-16-304 6 x 6 1.99 $ 31.94 

1 5/8 UB-163-25-16-304 6 x 6 1.79 $ 33.49 

1 5/8 UB-163-40-16-304 6 x 6 2.17 $ 37.13 

1 3/4 UB-175-25-16-304 6 x 6 1.94 $ 30.64 

1 3/4 UB-175-30-16-304 6 x 6 2.09 $ 32.04 

1 3/4 UB-175-40-16-304 6 x 6 2.34 $ 33.71 

1 7/8 UB-188-30-16-304 6 x 6 2.24 $ 38.77 

1 7/8 UB-188-40-16-304 6 x 6 2.57 $ 49.02 

1 7/8 UB-188-60-16-304 5.5 x 5.5 3.13 $ 52.24 

2 UB-200-30-16-304 6 x 6 2.40 $ 34.63 

2 UB-200-40-16-304 6 x 6 2.75 $ 36.56 

2 UB-200-60-16-304 5.5 x 5.5 3.34 $ 49.40 

2 1/8 UB-213-30-16-304 6 x 6 2.55 $ 46.39 

2 1/8 UB-213-40-16-304 6 x 6 2.93 $ 48.18 

2 1/8 UB-213-60-16-304 5.5 x 5.5 3.56 $ 56.41 

2 1/4 UB-225-40-16-304 6 x 6 3.11 $ 46.65 

2 1/2 UB-250-40-16-304 6 x 6 3.46 $ 50.20 

2 3/4 UB-275-40-16-304 6 x 6 3.82 $ 73.53 

3 UB-300-45-16-304 6 x 6 4.44 $ 84.50 

3 1/2 UB-350-45-16-304 6 x 6 5.19 $ 98.35 



1 1/4 UB-125-20-18-304 6 x 6 0.96 $ 26.30 

1 3/8 UB-138-25-18-304 6 x 6 1.16 $ 28.48 

1 1/2 UB-150-25-18-304 6 x 6 1.26 $ 29.70 

1 5/8 UB-163-25-18-304 6 x 6 1.36 $ 30.96 

1 3/4 UB-175-25-18-304 6 x 6 1.47 $ 28.85 

1 3/4 UB-175-40-18-304 6 x 6 1.82 $ 31.56 

1 7/8 UB-188-30-18-304 6 x 6 1.71 $ 35.09 

1 7/8 UB-188-40-18-304 6 x 6 1.96 $ 46.55 

1 7/8 UB-188-60-18-304 5.5 x 5.5 2.38 $ 49.71 

2 UB-200-30-18-304 6 x 6 1.82 $ 31.75 

2 UB-200-40-18-304 6 x 6 2.09 $ 33.40 

2 UB-200-60-18-304 5.5 x 5.5 2.54 $ 47.41 

2 1/8 UB-213-30-18-304 6 x 6 1.94 $ 43.51 

2 1/8 UB-213-40-18-304 6 x 6 2.22 $ 45.76 

2 1/8 UB-213-60-18-304 5.5 x 5.5 2.70 $ 54.43 

2 1/4 UB-225-40-18-304 6 x 6 2.36 $ 47.28 

2 3/8 UB-238-35-18-304 6 x 6 2.33 $ 47.51 

2 1/2 UB-250-40-18-304 6 x 6 2.63 $ 66.02 



1 1/2 UB-150-25-20-304 6 x 6 0.91 $ 25.69 

1 3/4 UB-175-30-20-304 6 x 6 1.14 $ 29.97 

2 UB-200-30-20-304 6 x 6 1.31 $ 30.49 

2 UB-200-40-20-304 6 x 6 1.50 $ 32.00 

Use 308 filler rod to 

weld 304 to 304 


weld 304 to mild steel 

Note: Tubing sizes are 

always described by 

outside diameter. 

Leg lengths are 

approximate, 

usually within 

+/- .25” 

Custom bending is 

available for quantities of 

50 pieces or more. 

2 

Burns Stainless LLC 949.631.5120 Monday - Friday 7:30 am to 4:30 pm fax 949.631.3184 burnsstainless.com

Surcharge may apply 

304 Stainless Steel J-bends 

304 Stainless Steel tubing combines excellent physical properties with a remarkable resistance to corrosive 

agents found in automotive exhaust emissions. It is the most cost-effective grade of nonmagnetic stainless 

steel for general applications, but some professional racing teams use the higher heat-resistant properties of 

aircraft grade 321 stainless steel. 

We have years of 

experience with stainless 

header fabrication and 

will be happy to advise 

our valued customers. 

J-Bends 304 Stainless - 16 gage (.065) 


1 3/4 JB-175-25-16-304 6 x 12 2.52 $35.76 

1 3/4 JB-175-30-16-304 6 x 12 2.67 $38.31 

1 7/8 JB-188-30-16-304 6 x 12 2.87 $47.50 

2 JB-200-30-16-304 6 x 12 3.07 $41.87 

2 1/8 JB-213-30-16-304 6 x 12 3.27 $51.67 

2 1/4 JB-225-40-16-304 6 x 12 3.86 $50.24 

2 1/2 JB-250-40-16-304 6 x 12 4.30 $53.77 

Stainless 

Tech Article 

on page 25 

J-Bends 304 Stainless - 18 gage (.049) 


1 3/4 JB-175-30-18-304 6 x 12 2.03 $ 35.63 

1 7/8 JB-188-30-18-304 6 x 12 2.18 $ 42.50 

2 JB-200-30-18-304 6 x 12 2.33 $ 37.92 

2 1/8 JB-213-30-18-304 6 x 12 2.48 $ 49.69 

2 1/4 JB-225-40-18-304 6 x 12 2.93 $ 50.64 

2 3/8 JB-238-35-18-304 6 x 12 2.94 $ 50.97 

2 1/2 JB-250-40-18-304 6 x 12 3.27 $ 72.74 

For U-bends and J-bends you can determine the CenterLine Radius 

(CLR) by measuring across the outside edges of the bend, 

subtracting the tubing O.D., and dividing by 2. 

A JB-225-40-16-304, for example, measures 10 1/4" across the 

outside edges, and has an O.D. of 2 1/4". Subtracting 2 1/4" from 

10 1/4" gives 8", and dividing by 2 equals 4"; so the CLR is 4 inches. 

UB: equal leg 180º 

JB: unequal leg 180º 

LB: 90º 

45: 45º 

15: 15º 

ST: straight 

Part Number System for Bends 

UB - 225 - 40 - 16 - 304 

Material: 

304 Stainless 


6061 Aluminum 

TItanium 

INCOnel 

Outside Diameter of Tubing 

Example: 225 = 2 1/4 

CLR: Center Line Radius 

Bend radius from center 

of bend to center of tube. 

Example: 40 = 4.0” CLR 

Gage, wall thickness 

16 = .065” 14 = .083” 

18 = .049” 17 = .058” 

20 = .035” 


3

304 Stainless Steel 90º and 15º Bends Surcharge may apply 

90º Bends 304 Stainless - 16 gage (.065) 


3/4 LB-075-20-16-304 4 x 12 0.76 $ 23.05 

1 LB-100-25-16-304 4 x 12 1.08 $ 25.00 

1 1/4 LB-125-20-16-304 4 x 12 1.31 $ 29.06 

1 3/8 LB-138-25-16-304 4 x 12 1.51 $ 29.27 

1 1/2 LB-150-25-16-304 4 x 12 1.65 $ 29.17 

1 5/8 LB-163-25-16-304 4 x 12 1.80 $ 33.49 

1 3/4 LB-175-30-16-304 4 x 12 2.02 $ 32.04 

1 7/8 LB-188-30-16-304 4 x 12 2.17 $ 38.77 

2 LB-200-20-16-304 6 x 6 1.69 $ 55.74 

2 LB-200-30-16-304 4 x 12 2.32 $ 34.63 

2 1/8 LB-213-30-16-304 4 x 12 2.47 $ 46.39 

2 1/4 LB-225-22-16-304 6 x 6 1.57 $ 56.53 

2 1/4 LB-225-40-16-304 4 x 12 2.82 $ 46.65 

2 3/8 LB-238-30-16-304 4 x 12 2.77 $ 68.15 

2 1/2 LB-250-25-16-304 4 x 6 1.96 $ 60.69 

2 1/2 LB-250-40-16-304 4 x 12 3.14 $ 50.20 

3 LB-300-30-16-304 3 x 6 2.33 $ 62.46 

3 LB-300-40-16-304 6 x 12 3.78 $ 55.72 

3 1/2 LB-350-35-16-304 4 x 8 3.48 $ 69.97 

4 LB-400-40-16-304 4 x 8 4.39 $ 78.27 

4 1/2 LB-450-45-16-304 8 x 8 5.92 $ 97.48 

5 LB-500-52-16-304 6 x 9 6.66 $130.45 



1 1/4 LB-125-20-18-304 4 x 12 1.00 $ 27.22 

1 3/8 LB-138-25-18-304 4 x 12 1.16 $ 28.48 

1 1/2 LB-150-25-18-304 4 x 12 1.26 $ 29.70 

1 5/8 LB-163-25-18-304 4 x 12 1.37 $ 30.96 



1 1/2 15-150-25-16-304 3 x 4 0.64 $ 20.85 

1 3/4 15-175-30-16-304 3.5 x 4.5 0.86 $ 22.39 

1 7/8 15-188-30-16-304 4 x 5 1.03 $ 26.06 

2 15-200-30-16-304 4 x 5 1.10 $ 24.16 

2 1/8 15-213-30-16-304 4 x 5 1.17 $ 32.65 

2 1/4 15-225-40-16-304 4 x 5 1.27 $ 33.23 

2 1/2 15-250-40-16-304 4 x 5 1.41 $ 38.03 

3 15-300-40-16-304 4 x 5 1.71 $ 47.61 



1 1/4 15-125-20-18-304 3 x 4 0.39 $ 20.07 

2 15-200-30-18-304 4 x 5 0.83 $ 22.84 

2 1/8 15-213-30-18-304 4 x 5 0.89 $ 31.34 

2 1/4 15-225-40-18-304 4 x 5 0.96 $ 33.53 

2 3/8 15-238-35-18-304 4 x 5 1.01 $ 41.06 

2 1/2 15-250-40-18-304 4 x 5 1.07 $ 33.90 

4 



304 Stainless Steel 45º Bends and Straight Tubing 



1 1/2 45-150-25-16-304 6 x 6 1.16 $ 25.09 

1 3/4 45-175-30-16-304 6 x 6 1.40 $ 26.81 

2 45-200-30-16-304 6 x 6 1.61 $ 28.59 

2 1/4 45-225-40-16-304 6 x 6 1.91 $ 37.04 

2 1/2 45-250-40-16-304 6 x 6 2.13 $ 42.27 

3 45-300-40-16-304 6 x 6 2.57 $ 49.64 

Straight tubing is sold by 

the foot, based on the 

total length of the tubing. 

It is cut to the length you 

specify. 

Lengths up to 8 feet can 

be shipped UPS. 

Straight 304 Stainless - 16 gage (.065) 

O. D. Part Number Lbs / ft. per foot 

3/4 ST-075-16-304 0.48 $ 4.65 

1 ST-100-16-304 0.65 $ 5.82 

1 1/4 ST-125-16-304 0.82 $ 8.25 

1 3/8 ST-138-16-304 0.91 $ 8.38 

1 1/2 ST-150-16-304 1.00 $ 8.32 

1 5/8 ST-163-16-304 1.08 $ 10.91 

1 3/4 ST-175-16-304 1.17 $ 9.20 

1 7/8 ST-188-16-304 1.26 $ 12.90 

2 ST-200-16-304 1.34 $ 10.63 

2 1/8 ST-213-16-304 1.43 $ 13.95 

2 1/4 ST-225-16-304 1.52 $ 12.81 

2 3/8 ST-238-16-304 1.60 $ 16.48 

2 1/2 ST-250-16-304 1.69 $ 14.26 

2 5/8 ST-263-16-304 1.78 $ 18.28 

2 3/4 ST-275-16-304 1.86 $ 16.63 

3 ST-300-16-304 2.04 $ 16.22 

3 1/4 ST-325-16-304 2.21 $ 31.34 

3 1/2 ST-350-16-304 2.39 $ 20.59 

4 ST-400-16-304 2.73 $ 24.26 

4 1/2 ST-450-16-304 3.08 $ 27.40 

5 ST-500-16-304 3.43 $ 31.78 

For quantities exceeding 15 feet, 

please call for pricing. 



1 1/4 ST-125-18-304 0.63 $ 7.15 

1 3/8 ST-138-18-304 0.70 $ 7.91 

1 1/2 ST-150-18-304 0.76 $ 8.63 

1 5/8 ST-163-18-304 0.82 $ 9.39 

1 3/4 ST-175-18-304 0.89 $ 8.13 

1 7/8 ST-188-18-304 0.96 $ 10.88 

2 ST-200-18-304 1.02 $ 9.04 

2 1/8 ST-213-18-304 1.09 $ 12.37 

2 1/4 ST-225-18-304 1.15 $ 13.12 

2 3/8 ST-238-18-304 1.22 $ 13.85 

2 1/2 ST-250-18-304 1.28 $ 9.93 

3 ST-300-18-304 1.54 $ 17.58 



1 1/2 ST-150-20-304 0.55 $ 6.23 

1 3/4 ST-175-20-304 0.64 $ 8.06 

2 ST-200-20-304 0.73 $ 8.35 

2 1/8 ST-213-20-304 0.78 $ 10.28 


5

304 Stainless Oval Tubing, Mandrel Bends and Transitions 


304 Stainless oval tubing is available in three sizes. 

The “Size” listed in the tables indicates 

that the oval tubing area is roughly 

equal to that size in round tubing. 

“Size” Height Width 

3 " 2 1/8” 3 1/2” 

3 1/2" 2 3/8” 4 1/8” 

4" 2 1/2” 4 3/4” 

Transitions from round to oval are available for each 

size, in either butt-weld or slip-over configurations. 

We make both long ( 12” ) and short ( 6” ) versions. 

Transitions - Round to Oval 

304 SS - 16 gage 

Size Part Number Short Long Short-slip Long-slip 

3 ROV-300-300 $ 50.00 $ 65.00 $ 75.00 $ 90.00 

3 1/2 ROV-350-350 $ 50.00 $ 65.00 $ 75.00 $ 90.00 

4 ROV 400-400 $ 50.00 $ 65.00 $ 75.00 $ 90.00 

Straight Oval 304 SS - 16 gage (.065) 


3 ST-300-304OVAL 2.21 $ 34.26 

3 1/2 ST-350-304OVAL 2.39 $ 38.67 

4 ST-400-304OVAL 2.73 $ 41.19 

Oval Bends Oval 304 SS - 16 gage (.065) 

Size Part Number Angle CLR Legs Wt./lbs Each 

3 45-300-S-304OVAL 45º 4.5 6 x 10 3.52 $ 80.83 

3 60-300-S-304OVAL 60º 4.5 6 x 10 3.78 $ 83.70 

3 90-300-S-304OVAL 90º 4.5 6 x 10 4.32 $ 83.70 

3 1/2 45-350-S-304OVAL 45º 5.5 6 x 10 4.12 $ 83.70 

3 1/2 60-350-S-304OVAL 60º 5.5 6 x 10 4.43 $ 87.63 

3 1/2 90-350-S-304OVAL 90º 5.5 6 x 10 5.05 $ 87.63 

3 1/2 45-350-L-304OVAL 45º 9 6 x 10 4.82 $ 87.63 

3 1/2 60-350-L-304OVAL 60º 9 6 x 10 5.37 $ 93.12 

3 1/2 90-350-L-304OVAL 90º 9 6 x 10 6.46 $ 93.12 

6 



321 Stainless Steel U-bends and 90º Bends 



1 1/2 UB-150-25-16-321 6 x 6 1.65 $ 57.26 

1 5/8 UB-163-25-16-321 6 x 6 1.80 $ 42.87 

1 3/4 UB-175-25-16-321 6 x 6 1.94 call for price 





1 7/8 UB-188-60-16-321 5.5 x 5.5 3.13 call for price 

2 UB-200-30-16-321 6 x 6 2.40 $ 67.48 

2 UB-200-40-16-321 6 x 6 2.75 $ 70.62 

2 UB-200-60-16-321 5.5 x 5.5 3.34 $ 83.99 

2 1/4 UB-225-40-16-321 6 x 6 3.11 $ 99.21 

2 1/2 UB-250-40-16-321 6 x 6 3.46 $ 78.04 


weld 321 to 321 


weld 321 to 304 


weld 321 to mild steel 



1 5/8 UB-163-25-18-321 6 x 6 1.36 $ 65.17 

1 3/4 UB-175-25-18-321 6 x 6 1.47 $ 49.67 

1 3/4 UB-175-30-18-321 6 x 6 1.59 $ 52.80 

1 3/4 UB-175-40-18-321 6 x 6 1.82 $ 56.55 

1 7/8 UB-188-30-18-321 6 x 6 1.71 $ 57.04 

1 7/8 UB-188-40-18-321 6 x 6 1.96 $ 63.87 

1 7/8 UB-188-60-18-321 5.5 x 5.5 2.38 $ 69.62 

2 UB-200-30-18-321 6 x 6 1.82 $ 59.00 

2 UB-200-40-18-321 6 x 6 2.09 $ 61.29 

2 UB-200-60-18-321 5.5 x 5.5 2.54 $ 72.32 

2 1/8 UB-213-30-18-321 6 x 6 1.94 $ 78.22 



1 3/4 UB-175-30-20-321 6 x 6 1.14 $ 52.07 

1 3/4 UB-175-40-20-321 6 x 6 1.31 $ 55.75 



1 7/8 UB-188-60-20-321 5.5 x 5.5 1.71 call for price 

2 UB-200-30-20-321 6 x 6 1.31 $ 56.84 

2 UB-200-40-20-321 6 x 6 1.50 $ 58.96 

Note: leg lengths 

are approximate, 

usually within 

+/- .25” 



1 7/8 LB-188-40-20-321 6 x 6 1.05 call for price 

1 7/8 LB-188-60-20-321 6 x 6 1.23 call for price 

2 LB-200-40-20-321 6 x 6 1.12 $ 50.45 

2 LB-200-60-20-321 6 x 6 1.31 $ 61.63 

2 1/8 LB-213-60-20-321 6 x 6 1.39 $ 78.86 


7

321 Stainless Steel Straight Tubing, Service Costs 


321 Stainless exhibits superior resistance to fatigue and cracking at elevated temperatures compared to 304. 

It is highly recommended for turbo- and super-charged applications, in racing and street applications, and is 

frequently the material of choice of Winston Cup and Pro Stock fabricators because 321 can be used 

effectively in thinner gages than 304, reducing the weight of a set of headers by 25% or more. 


Tech Article 

on page 25 

Straight tubing is sold by 

the foot, based on the 

total length of the tubing. 

It is cut to the length you 

specify. 

Lengths up to 8 feet can 

be shipped UPS. 

For quantities exceeding 15 feet, 

please call for pricing. 



1 1/2 ST-150-16-321 1.00 $ 24.16 

1 5/8 ST-163-16-321 1.09 $ 15.75 

1 3/4 ST-175-16-321 1.17 call for price 


2 ST-200-16-321 1.34 $ 32.24 

2 1/4 ST-225-16-321 1.52 $ 44.50 

2 1/2 ST-250-16-321 1.69 $ 33.60 



1 1/2 ST-150-18-321 0.76 $ 34.60 

1 5/8 ST-163-18-321 0.82 $ 32.42 

1 3/4 ST-175-18-321 0.89 $ 19.64 

1 7/8 ST-188-18-321 0.96 $ 21.92 

2 ST-200-18-321 1.02 $ 23.97 



1 1/2 ST-150-20-321 0.55 $ 17.52 

1 3/4 ST-175-20-321 0.64 $ 19.26 


2 ST-200-20-321 0.73 $ 21.76 

2 1/8 ST-213-20-321 0.78 $ 34.22 

2 1/4 ST-225-20-321 0.83 $ 25.71 

2 1/2 ST-250-20-321 0.92 $ 32.43 

3 ST-300-20-321 1.11 $ 31.12 

3 1/2 ST-350-20-321 1.30 $ 34.50 

Service Costs 

Welding single weld, including hand fitting 

mild steel $10.00 

stainless $15.00 

Welding and cutting hole for O2 ring, stainless $40.00 

Welding stainless bracket to collector $10.00 

Cutting straight tubing or tailpipe rings, per cut $5.00 

Special cutting on transition or megaphone, per cut $10.00 

Add reverse cone on megaphone $60.00 

Expand tubing for slip joint, up to 2 1/4” $5.00 

Expand tubing for slip joint, over 2 1/4” $8.00 

8 



6061 Aluminum U-bends, 90º Bends, and 45º Bends 

U-Bends 

6061 Aluminum - O condition 


3/4 UB-075-20-16-6061 4 x 4 0.20 $ 23.72 

1 UB-100-25-16-6061 4 x 4 0.30 $ 26.02 

1 1/4 UB-125-20-18-6061 4 x 4 0.26 $ 26.91 

1 3/8 UB-138-25-16-6061 4 x 4 0.42 $ 27.62 

1 1/2 UB-150-25-16-6061 4 x 4 0.46 $ 27.58 

1 5/8 UB-163-25-17-6061 4 x 4 0.44 $ 29.22 

1 3/4 UB-175-30-16-6061 4 x 4 0.59 $ 30.49 

1 7/8 UB-188-30-17-6061 4 x 4 0.57 $ 31.48 

2 UB-200-30-16-6061 4 x 4 0.67 $ 32.57 

2 1/8 UB-213-30-16-6061 4 x 4 0.72 $ 43.18 

2 1/4 UB-225-40-16-6061 4 x 4 0.90 $ 43.13 

2 1/2 UB-250-40-16-6061 5.7 x 5.7 1.17 $ 52.21 

2 3/4 UB-275-40-16-6061 5.7 x 5.7 1.11 $ 83.41 

3 UB-300-45-16-6061 6 x 6 1.54 $ 91.71 

4 UB-400-60-16-6061 8 x 5 2.53 $ 132.43 

For intake and cooling 

systems 6061 aluminum is the 

least expensive and most 

versatile of the heat treatable 

alloys. 

In the annealed “0” condition it 

has good formability for 

bending. The full-temper T6 

properties may be obtained by 

solution heat treating and 

artificial aging after welding. If 

you need advice about 

working with aluminum, 

please give us a call. 

90º Bends 6061 Aluminum - O condition 


3/4 LB-075-20-16-6061 4 x 12 0.26 $ 26.96 

1 LB-100-25-16-6061 4 x 12 0.37 $ 28.91 

1 1/4 LB-125-20-18-6061 4 x 12 0.35 $ 31.59 

1 3/8 LB-138-25-16-6061 4 x 12 0.52 $ 30.97 

1 1/2 LB-150-25-16-6061 4 x 12 0.57 $ 30.92 

1 5/8 LB-163-25-17-6061 4 x 12 0.56 $ 33.03 

1 3/4 LB-175-25-16-6061S 3 x 6 0.44 $ 26.32 

1 3/4 LB-175-25-16-6061 4 x 12 0.67 $ 32.49 

1 7/8 LB-188-30-17-6061 4 x 12 0.67 $ 33.77 

2 LB-200-30-16-6061 4 x 12 0.80 $ 35.02 

2 1/8 LB-213-30-16-6061 4 x 12 0.85 $ 46.33 

2 1/4 LB-225-40-16-6061 4 x 12 0.97 $ 46.40 

2 1/2 LB-250-40-16-6061 4 x 12 1.09 $ 51.78 

2 3/4 LB-275-40-16-6061 6 x 12 1.29 $ 75.11 

3 LB-300-30-16-6061 3 x 6 0.81 $ 75.50 

3 LB-300-40-16-6061 5.5 x 12 1.40 $ 65.05 

3 1/2 LB-350-35-16-6061 4 x 8 1.31 $ 84.60 

4 LB-400-40-16-6061 4 x 11 1.68 $101.60 

4 1/2 LB-450-45-16-6061 5 x 9 1.87 $143.10 

5 LB-500-53-11-6061 5 x 6 3.47 $128.87 

See the Aluminum 

Tech Article on 

page 28 

Note: Tubing sizes are 

always described by 

outside diameter. 

45º Bends 6061 Aluminum - O condition 


1 1/2 45-150-25-16-6061 5.5 x 5.5 0.37 $25.32 

1 3/4 45-175-25-16-6061 5.5 x 5.5 0.44 $26.32 

2 45-200-30-16-6061 5.5 x 5.5 0.50 $27.84 

2 1/4 45-225-40-16-6061 5.5 x 5.5 0.62 $36.51 

2 1/2 45-250-40-16-6061 5.5 x 5.5 0.69 $41.10 

3 45-300-40-16-6061 5.5 x 5.5 0.83 $52.73 


9

6061 Aluminum Straight Tubing 


Use 5356 rod for 

maximum strength 

Use 4043 rod for max 

corrosion resistance 

Aluminum is not recommended 

as an exhaust system material. 

Straight 6061 Aluminum - T 6 


3/4 ST-075-16-6061 0.16 $ 3.54 

1 ST-100-16-6061 0.22 $ 4.55 

1 1/4 ST-125-18-6061 0.22 $ 6.20 

1 3/8 ST-138-16-6061 0.31 $ 5.76 

1 1/2 ST-150-16-6061 0.34 $ 5.72 

1 5/8 ST-163-17-6061 0.34 $ 6.96 

1 3/4 ST-175-16-6061 0.40 $ 6.64 

1 7/8 ST-188-17-6061 0.39 $ 7.31 

2 ST-200-16-6061 0.46 $ 8.03 

2 1/8 ST-213-16-6061 0.50 $ 11.29 

2 1/4 ST-225-16-6061 0.52 $ 9.42 

2 1/2 ST-250-16-6061 0.58 $ 10.40 

2 3/4 ST-275-16-6061 0.64 $ 11.57 

3 ST-300-16-6061 0.70 $ 14.17 

3 1/2 ST-350-16-6061 0.82 $ 18.09 

4 ST-400-16-6061 0.95 $ 22.55 

4 1/2 ST-450-16-6061 1.06 $ 38.74 

5 ST-500-16-6061 1.18 $ 38.74 

10 



Inconel Tubing and Mandrel Bends 

U-Bends Inconel - 18 gage (.049) 

O. D. Part Number 

1 3/4 UB-175-30-18-INCO 

1 3/4 UB-175-40-18-INCO 

1 7/8 UB-188-30-18-INCO 

1 7/8 UB-188-40-18-INCO 

2 UB-200-30-18-INCO 

2 UB-200-40-18-INCO 

90º Bends Inconel - 20 gage (.035) 


1 3/4 LB-175-30-20-INCO 

1 3/4 LB-175-40-20-INCO 

1 7/8 LB-188-30-20-INCO 

1 7/8 LB-188-40-20-INCO 

2 LB-200-30-20-INCO 

2 LB-200-40-20-INCO 

110º Bends Inconel - 22 gage 


1 7/8 110-188-20-22-INCO 

1 7/8 110-188-25-22-INCO 

1 7/8 110-188-30-22-INCO 

1 7/8 110-188-40-22-INCO 

1 7/8 110-188-50-22-INCO 

2 110-200-20-22-INCO 

2 110-200-25-22-INCO 

2 110-200-30-22-INCO 

2 110-200-40-22-INCO 

2 110-200-50-22-INCO 

2 110-200-60-22-INCO 

2 1/8 110-213-21-22-INCO 

2 1/8 110-213-25-22-INCO 

2 1/8 110-213-30-22-INCO 

2 1/8 110-213-40-22-INCO 

2 1/8 110-213-50-22-INCO 

2 1/8 110-213-60-22-INCO 

This range 

of 110º 

thin-wall 

bends are 

also available 

in 20 gage 

Inconel. 

Please call 

for price and 

delivery. 

Inconel 625 excels in 

applications such as Rotary 

engines and extreme duty 

turbocharger exhausts. It 

maintains its strength at 

temperatures greater than 

1800º F, where 321 SS is 

unsuitable. 

Inconel can be used in thinner 

gages in header systems, 

compared to 304 or 321 

stainless, resulting in a lighter 

weight product with equal or 

better mechanical properties. 

See the Inconel technical paper 

on page 27. 

The Inconel parts listed in this 

section are normally special 

order items. We may have 

stock on some items from time 

to time. Please call for price 

and availability. Lead-time for 

special order items is 

approximately 2-3 weeks and 

is dependent on material 

availability and production 

schedule. 

Straight 

Inconel-18,20 and 22 gage 

O. D. Part Number Lbs / ft per foot 

1 3/4 ST-175-22-INCO 0.55 call for price 






2 ST-200-22-INCO 0.63 call for price 





Inconel pricing is extremely volatile. Please call for current prices and availability. 


11

Racing Merge Collectors - General Information 


Burns Stainless Merge Collectors are in widespread use by top engine builders in NHRA Pro Stock Car, 

Bike, and most other classes, and are very popular in NASCAR, ALMS, FIA-GT, Trans-Am, and IRL. 

Fabricated from pre-bent tubing to form a pyramid inside, Burns Stainless merge 

collectors combine high flow and high velocity to increase and broaden an 

engine's torque curve all the way to the horsepower peak and beyond. 

They feature the highest quality fabrication and welding, and each one is 

completely hand finished inside for proper flow. 

For drag racing and similar applications where a tailpipe is not required, 

megaphones fitted with reverse cones are invariably the best option. They make 

the most horsepower, maintain the highest and smoothest torque curve, and, on 

well developed engine combinations with optimally short header tube lengths and 

a well chosen collector outlet diameter, offer the highest potential power past the 

peak without sacrificing the lower end. 

Here are our five common collector outlet options. 

Each is available with 2 into 1, 3 into 1, 4 into 1, 5 into 1, and 6 into 1 collectors. 

To fulfull your collector order, we need to determine 4 basic dimensions. 

( 5 into 1 and 6 into 1 collectors 

are special order items; 

please call for price and info ) 

1 

1 

Inlet Diameter - the outside diameter of your final header tubes. 

straight extension 

2 

Collector Outlet Diameter - normally determined by our X-design 

computer program ( see page 16 ). There is no standard outlet size; 

each collector system is based on your engine’s specs. 

2 

V-Band Flange 

3 

Style of Outlet - Long or Short Transition, or Megaphone. 

Generally, if your vehicle uses a tailpipe, a transition and 

tailpipe ring will be needed. 

If you don’t have to run a tailpipe, we recommend using a 

megaphone for maximum horsepower and powerband. 

3 

Short Transition 

4 

4 

Final Outlet Diameter and Configuration - 

usually a tailpipe ring for use with a 

transition. A tailpipe ring is described by its 

outside diameter; it slips inside your tailpipe, 

and is normally 2” long. 

If you plan on a megaphone, a reverse cone is 

highly recommended. 

Long Transition 

Megaphone 

The best way to order merge collectors: 

1. Fill out the Race Engine Spec. Form on the last 

page of the catalog, or on our web-site, and 

fax,mail or email it to us. 

2. We’ll analyze your engine with X-design and call 

you with the results and our recommendation. 

3. Your custom collector order can then be completed 

to your specs and shipped, usually within 14 days. 

12 



Base Merge Collectors 

4-into-1 Base Collectors 

Primary OD Part Number Mild Steel 304 SS 321 SS 

1 1/4 MC4-125 $ 250.00 $ 278.00 $ 307.00 

1 3/8 MC4-138 $ 253.00 $ 282.00 $ 311.00 

1 1/2 MC4-150 $ 253.00 $ 282.00 $ 311.00 

1 5/8 MC4-163 $ 260.00 $ 290.00 $ 319.00 

1 3/4 MC4-175 $ 260.00 $ 290.00 $ 319.00 

1 7/8 MC4-188 $ 259.00 $ 289.00 $ 319.00 

2 MC4-200 $ 260.00 $ 291.00 $ 320.00 

2 1/8 MC4-213 $ 280.00 $ 312.00 $ 343.00 

2 1/4 MC4-225 $ 278.00 $ 311.00 $ 342.00 

2 3/8 MC4-238 $ 307.00 $ 339.00 $ 372.00 

2 1/2 MC4-250 $ 290.00 $ 322.00 $ 356.00 

2 5/8 MC4-263 $ 359.00 $ 400.00 n/a 

2 3/4 MC4-275 $ 370.00 $ 412.00 n/a 



1 1/4 MC3-125 $ 205.00 $ 235.00 $ 266.00 

1 3/8 MC3-138 $ 207.00 $ 238.00 $ 270.00 

1 1/2 MC3-150 $ 207.00 $ 238.00 $ 270.00 

1 5/8 MC3-163 $ 212.00 $ 245.00 $ 276.00 

1 3/4 MC3-175 $ 212.00 $ 245.00 $ 276.00 

1 7/8 MC3-188 $ 212.00 $ 245.00 $ 276.00 

2 MC3-200 $ 213.00 $ 246.00 $ 277.00 

2 1/8 MC3-213 $ 228.00 $ 263.00 $ 297.00 

2 1/4 MC3-225 $ 227.00 $ 261.00 $ 295.00 

2 3/8 MC3-238 $ 264.00 $ 303.00 $ 342.00 

2 1/2 MC3-250 $ 236.00 $ 271.00 $ 307.00 

Base Collectors are available 

in 304 Stainless and Mild 

Steel. We also make all sizes 

except 2 5/8 and 2 3/4 in 

321 SS. 

Collectors are made to 

order. Please call for lead 

time on collectors. 

The standard wall thickness is 

.065” (16 gage), and we can 

supply many thin wall 321 

sizes. 

Inconel collectors are available 

by special order in some sizes. 

Please call for details. 



1 1/4 MC2-125 $ 91.00 $ 110.00 $ 139.00 

1 3/8 MC2-138 $ 91.00 $ 110.00 $ 139.00 

1 1/2 MC2-150 $ 91.00 $ 110.00 $ 139.00 

1 5/8 MC2-163 $ 98.00 $ 116.00 $ 145.00 

1 3/4 MC2-175 $ 98.00 $ 122.00 $ 151.00 

1 7/8 MC2-188 $ 104.00 $ 127.00 $ 156.00 

2 MC2-200 $ 104.00 $ 133.00 $ 162.00 

2 1/8 MC2-213 $ 110.00 $ 139.00 $ 168.00 

2 1/4 MC2-225 $ 116.00 $ 145.00 $ 174.00 

2 3/8 MC2-238 $ 139.00 $ 168.00 $ 197.00 

2 1/2 MC2-250 $ 139.00 $ 169.00 $ 197.00 

2 5/8 MC2-263 $ 163.00 $ 203.00 n/a 

2 3/4 MC2-275 $ 162.00 $ 203.00 n/a 

3 MC2-300 $ 145.00 $ 173.00 $ 203.00 

3 1/2 MC2-350 $ 162.00 $ 203.00 $ 261.00 

5 into 1 and 6 into 1 merge 

collectors are special orders. 

If you’re considering a 6 into 

1, please call to discuss the 

options. We build lots of 6 

into 1 collectors, especially for 

turbo applications, but the 

performance of a 6-2-1 

system is far superior to a 6- 

into-1 in almost all cases. 

If horsepower and power 

bandwidth are your primary 

goals, think about a 6-2-1 

setup. 


13

Double-Slip Turbo Collectors and Splayed Collector Options 


Double-Slip Turbo Collectors achieve a tight, weld-free seal at the 

header-collector junction by providing exterior slip tubes, which are 

welded to your existing header tubes. 

The slip tubes provide an extra seat and sealing surface for the 

collector, and allow the header system to grow and shrink over a 

wide temperature range while greatly reducing the potential stress 

and cracking which is typical of welded stainless turbo headers. 

Both the collector, and the header tubes in 

this system are spaced 1/8” farther apart 

to accommodate the additional slip tubes. 

Weld the slips to your existing header 

tubes using the collector as a jig. 

321 Stainless is the standard material 

for our Double-Slip Turbo Collectors. 

T3, T4, and V-band 

flanges are in stock. 

We can usually 

fabricate a collector 

for your particular 

inlet flange. 

In addition to our standard, high-velocity 

15º merge collectors, we offer a shorter, 

25º turbo collector for applications where 

space is limited. They’re about 2/3 the 

length of our standard collectors. 

We recommend our 15º turbo collectors 

for extreme output, high rpm use. 

4-into-1 Double-Slip Collectors 

Inlet Size Part Number each 

1 1/2 MC4-150-DST $ 366.00 

1 5/8 MC4-163-DST $ 375.00 

1 3/4 MC4-175-DST $ 375.00 

1 7/8 MC4-188-DST $ 375.00 

2 MC4-200-DST $ 376.00 

2 1/8 MC4-213-DST $ 399.00 

2 1/4 MC4-225-DST $ 398.00 

2 3/8 MC4-238-DST $ 427.00 

2 1/2 MC4-250-DST $ 412.00 



1 1/2 MC3-150-DST $ 312.00 

1 5/8 MC3-163-DST $ 318.00 

1 3/4 MC3-175-DST $ 318.00 

1 7/8 MC3-188-DST $ 318.00 

2 MC3-200-DST $ 319.00 

2 1/8 MC3-213-DST $ 339.00 

2 1/4 MC3-225-DST $ 337.00 

2 3/8 MC3-238-DST $ 384.00 

2 1/2 MC3-250-DST $ 349.00 



1 1/2 MC2-150-DST Surcharge may apply $ 166.00 

1 5/8 MC2-163-DST $ 172.00 

1 3/4 MC2-175-DST $ 179.00 

1 7/8 MC2-188-DST $ 184.00 

2 MC2-200-DST $ 189.00 

2 1/8 MC2-213-DST $ 195.00 

2 1/4 MC2-225-DST $ 202.00 

2 3/8 MC2-238-DST $ 225.00 

2 1/2 MC2-250-DST $ 225.00 

All of our merge collectors are available 

with splayed inlets at no extra cost. 

Splayed Collector options 

Splayed inlets allow the header builder 

an additional degree of freedom in 

routing the tubes, and are often 

necessary for high rpm, short-length 

designs, as well as turbo headers with 

tight space requirements. 

full-splayed 

half-splayed 

2-into-1 configurations can be full-splayed (with a 

30º included angle), or half-splayed, with one splayed 

leg and one conventional leg (15º included angle). 

14 



Transitions and Megaphones, 

Transitions 

Transitions are swaged tubes that taper from a small diameter to 

a larger diameter. We make them with either 14º ( Long taper ) or 

30º ( Short taper ) included angles, and normally provide a 2” long 

straight section at the small end. 

Transitions 

Mild Steel, 304, 321 Stainless 

Small Dia. Part Number Max Big End Mild Stl 304 SS 321 SS 

1 1/4 RD-125- 1 3/4 $ 20.41 $ 25.66 n/a 

1 3/8 RD-138- 2 $ 21.50 $ 26.75 n/a 

1 1/2 RD-150- 2 1/4 $ 21.50 $ 26.75 $ 32.21 

1 5/8 RD-163- 2 3/8 $ 22.05 $ 27.30 $ 32.76 

1 3/4 RD-175- 2 1/2 $ 22.05 $ 27.30 $ 32.76 

1 7/8 RD-188- 2 5/8 $ 22.60 $ 27.85 $ 33.31 

2 RD-200- 2 3/4 $ 22.60 $ 27.85 $ 33.31 

2 1/8 RD-213- 2 7/8 $ 23.14 $ 28.39 $ 33.85 

2 1/4 RD-225- 3 $ 23.14 $ 28.39 $ 33.85 

2 3/8 RD-238- 3 1/8 $ 24.78 $ 30.03 n/a 

2 1/2 RD-250- 3 1/4 $ 24.78 $ 30.03 $ 35.49 

2 5/8 RD-263- 3 3/8 $ 25.33 $ 30.58 n/a 

2 3/4 RD-275- 3 1/2 $ 25.33 $ 30.58 n/a 

3 RD-300- 3 3/4 $ 25.33 $ 30.58 $ 36.04 

3 1/4 RD-325- 4 $ 27.51 $ 37.13 n/a 

3 1/2 RD-350- 4 1/4 $ 29.69 $ 34.94 $ 40.40 

4 RD-400- 4 3/4 $ 31.88 $ 37.13 $ 42.59 

To order, pick your small diameter and a large diameter not 

larger than the “max big end”, and specify either Long or Short 

taper by adding L or S to the part number. 

Example: RD-250-325-L has a 2 1/2 small end, a 3 1/4 big end, 

and a long taper. 

Megaphones 

In the table here, the Small Dia. is the outside 

diameter of the tubing the transition is made 

from, and the Max Big End is the largest 

diameter to which it can be swaged. The large 

diameter of your transition can be anything up 

to the Max Big End. 

To calculate the length of the tapered section, 

subtract the small diameter from the large 

diameter and multiply by 4.07 ( Long ) or 1.87 

( Short ). 

Typically, the tapered section of a Long 

Transition is around 3”, and a Short one is 

about 1.4”. 

Transitions 

6061 Aluminum 

Small dia. Part Number Max Big End 6061 

1 1/4 RD-125- 1 3/4 $ 25.66 

1 3/8 RD-138- 1 7/8 $ 26.21 

1 1/2 RD-150- 2 $ 26.21 

1 5/8 RD-163- 2 1/8 $ 26.75 

1 3/4 RD-175- 2 1/4 $ 26.75 

1 7/8 RD-188- 2 3/8 $ 27.30 

2 RD-200- 2 1/2 $ 27.30 

2 1/8 RD-213- 2 5/8 $ 27.85 

2 1/4 RD-225- 2 3/4 $ 27.85 

2 1/2 RD-250- 3 $ 28.39 

2 3/4 RD-275- 3 1/4 $ 30.58 

3 RD-300- 3 1/2 $ 30.58 

3 1/2 RD-350- 4 $ 31.67 

4 RD-400- 4 1/2 $ 35.18 

Megaphones are recommended for most applications that do not use tailpipes. They frequently augment the 

entire power curve, and enhance power above the peak rpm. Our Megaphones are rolled and seam welded, 

in mild steel or 20 gage 304 Stainless. 

Megaphones 

Mild Steel, 304 Stainless 

Part Number Small dia. Large dia. Length Angle Mild Steel 304 20 g. 

MEG-15035 1 1/2 3 1/2 17.5 6.5º $ 24.57 $ 30.03 

MEG-24115 2 4 11.5 9º $ 20.20 n/a 

MEG-24175 2 4 17.5 6.5º $ 24.57 $ 30.03 

MEG-25045 2 1/2 4 1/2 14.5 8 º $ 27.30 $ 32.76 

MEG-35145 3 5 14.5 8 º $ 27.30 $ 32.76 

This is our typical drag race setup - merge 

collector / megaphone / reverse-cone, and 

it’s very successful in all kinds of 

competition, from Pro Stock to Truck Pulling 

to Air racing. 

A megaphone/reverse-cone welded unit 

is available only as part of 

a complete, engineered 

merge collector system. 


15

X-Design TM Computer Analysis Service for Racing Exhaust Systems 

X-design - Burns Stainless’ unique exhaust system computer analysis program. 

X-design has evolved from our extremely successful compared to a mass-produced “cannister” style 

DesignSYS program in response to a growing need in setup. 

the community of motorsports racers and engine The rub is that the merge collector must be designed 

builders to effectively manage the incredible amount for your particular engine. Your camshaft and valves, 

of information and data essential to a competitive your combustion chamber, compression ratio, exhaust 

effort. 

port, and your header configuration, all communicate 

intimately with the merge collector, especially when 

Our core business of designing and building racing your motor is working at greater than 100% 

merge collectors and header systems has 

demonstrated that current race engines respond 

dramatically to small variations in the exhaust tract 

when volumetric efficiency exceeds 100%. 

The most critical area is the outlet of the merge 

collector - its shape and diameter. In a highly 

developed racing engine, the collector outlet interacts 

strongly with elements as far removed as the intake 

valve and camshaft and all the way to the tailpipe. 

In a typical mass-produced drag header, for instance, 

the header tubes are frequently about 10 to 20% 

longer than necessary and joined into a large, 

straight, “cannister” style collector. This setup can 

produce good horsepower in a relatively narrow rpm 

range, and is usually sized to maximize the 

horsepower peak. 

Assuming you can live with a relatively narrow power 

band, you can win races with headers like this, but 

conditions have to be just right, and you may need to 

play around with 2 or 3 different sets of headers 

during a weekend of racing. 

Merge collectors change the game fundamentally. 

When properly designed, they keep or augment the 

horsepower peak, and fill in the power curve from the 

torque peak on up. It is not uncommon to see gains 

of 15 to 25 hp with a good merge collector system, 

volumetric efficiency. If the basic collector 

parameters are not designed with these factors in 

mind, your motor won’t realize its potential. 

X-design, used in conjunction with our Race Engine 

Specification Form, virtually assures you ( and us at 

Burns Stainless ) that our merge collectors will 

provide you with state-of-the-art performance. We 

are constantly refining and updating the program, and 

based on feedback each week from our customers, 

the success rate is very high. In a community where 

the state of the art changes at a dizzying pace, 

X-design is an essential tool in the quest to compete. 

Please take a look at the Race Engine Specification 

Form on page 32. If you think there might be some 

more ponies hiding in your race engine, fill out the 

form and fax or mail it to us. We’ll get back to you, 

usually within 48 hours, and help you decide how to 

get the best results for your competitive effort. 

The one thing that X-design doesn’t take into account is the changing conditions 

during your day or weekend at the races. When track or atmospheric factors call for 

a change of tune, our B-TEC adjustable race collectors are the answer. See page 17. 

16 



DynoSYS TM and B-TEC TM Adjustable Collectors 

DynoSYS 

DynoSYS is a unique adjustable venturi stainless steel merge collector system that simplifies 

dyno testing, enabling you to quickly and painlessly tune your header dimensions and 

determine the correct collector outlet size for various engine combinations. 

DynoSYS offers these distinct advantages 

● Saves cost when compared to buying separate collectors for back to back testing. 

● Allows easier, simpler R&D testing when tuning header system to new engine 

configurations. 

● Eliminates the hassle of changing hot collectors on dyno headers - just slide out one 

venturi group and slide in another - leaving the collectors in place. 

● Custom built to your primary and outlet size specifications. 

● Venturi angles, both convergent and divergent, have been 

extensively tested. 

● Venturi sized to your specification 

(your choice, but please consider X-design recommendation). 

● Exhaust system design consulting using our X-design 

parametric software (see page 16 for details ). 

● Price quote on request 

B-TEC Adjustable Collectors 

B-TEC, the Burns Tunable Exhaust Collector, is the on-track evolution of our DynoSYS 

adjustable merge collector, originally designed to assist in the dyno testing of collectors on 

different engine combinations. 

In the last couple of years, our B-TEC adjustable collector system has established its reputation 

as an indispensable tool for serious drag racers. It is used by many of the fastest NHRA Pro 

Stock Cars, and some of the top Pro Stock Motorcycles, and is becoming increasingly popular in 

Competition and Sportsman classes. 

Available in 2, 3, 4, and 5 into 1 configurations, B-TEC adds about 8 to 

10 ounces of extra weight to each collector. The minimum set consists 

of a merge collector with adapter neck, one venturi insert, and a special 

slip megaphone with reverse cone. 

This setup can usually accommodate 3 different venturi diameters, but 

sometimes the smaller venturi selections need extra length, and an 

extension collar is needed. 

You gain the ability to quickly and precisely tune your torque curve based on track and 

atmospheric conditions, and to fine-tune the header system to mechanical changes at the track 

on race day. 


17

X-pipes,Y-pipes and V-Band Clamps 


X-Pipes 

X-Pipes are produced using the same techniques as our 2-1 merge collectors. 

They are available with parallel inlets, splayed inlets, or a combination of the 

two. In addition, you can specify the center to center distance for both the 

inlet and outlet pipes, and the leg lengths can be staggered if necessary. 

The junction area can be round or oval, but the 

actual shape and area at the junction is critical for 

optimum performance.Please call for our 

recommendation. 

The price of an X-pipe is calculated by taking the price of 

two 2-into-1 Base Collectors (page 13) and adding 

$50.00 finishing cost. 

Y-Pipes 

Y-Pipes are nearly identical to our 2-1 merge collectors, and are 

available with parallel, splayed, or half-splayed inlets. The center 

to center distance is your option, but the choice of outlet (neckdown) 

diameter is very important for peak performance. A 

transition and tailpipe ring are the usual outlet options. 

In general, to calculate the price of your Y-Pipe, find the price of 

the appropriate 2-into-1 collector, and add $65.00 for stainless, 

or $55.00 for mild steel. 

V-Band Clamps 

For a close tolerance, gasketless tube coupling, V-Band clamps are the high-tech alternative to the standard 

3-bolt flange. 

Stainless V-Band Assemblies 

Size Part Number Assembly Clamp Only Flange Only 

2 VB-200-ASSY $ 78.40 $46.70 $30.90 

2 1/4 VB-225-ASSY $ 78.40 $46.70 $30.90 

2 1/2 VB-250-ASSY $ 78.40 $46.70 $30.90 

3 VB-300-ASSY $ 78.40 $46.70 $30.90 

3 1/2 VB-350-ASSY $ 78.40 $46.70 $30.90 

4 VB-400-ASSY $ 87.60 $46.70 $39.20 

Included are two V-Band weld-on 

flanges and one V-Band clamp per 

assembly. All stainless 

construction.Flange or clamp 

available separately - see price list. 

To achieve close tolerance alignment 

between the tubes being joined, let one 

of the tubes protrude about 1/4” when 

welding the flange. It will then register 

nicely into the opposing flange. 

.25 min. 

18 



Flat-band Clamps, Silicone Hose, Hump Hose and Reducers 

T-bolt flat band clamps are an alternative 

to U-bolt muffler clamps for 

clamping close tolerance slip 

connections on tubing. 

Flat band clamps do not 

permanently crimp the slit 

tubing, allowing easier 

removal after assembly. 

Stainless steel strap, plated 

steel T-bolt and nut 

Flat Band Clamps ( T-bolt ) 

Flat Band Clamps 


Size Part Number Min. dia. Max dia. Silicone Hose Size Each 

1 3/4 FB-175 1.75 2.00 SH-150 $ 9.49 

2 FB-200 2.00 2.25 SH-175 $ 9.49 

2 1/4 FB-225 2.25 2.56 SH-200 $ 9.49 

2 1/2 FB-250 2.50 2.81 SH-225 $ 9.49 

2 3/4 FB-275 2.75 3.00 SH-250 $ 9.49 

3 FB-300 3.00 3.31 SH-275 $ 9.49 

3 1/4 FB-325 3.25 3.56 SH-300 $ 9.49 

3 1/2 FB-350 3.50 3.81 SH-325 $ 9.49 

3 3/4 FB-375 3.75 4.06 SH-350 $ 9.49 

4 FB-400 4.00 4.31 SH-375 $ 10.49 

4 1/2 FB-450 4.31 4.62 SH-400 $ 10.49 

Silicone Hose , Hump Hose and Reducers- Silicone High Perf, 4 ply 

Silicone Hose - High Performance 4 ply 

ID Part Number OD Per / foot 

1/2 SH-050 7/8 $ 8.96 

3/4 SH-075 1 1/8 $ 10.94 

1 SH-100 1 3/8 $ 12.89 

1 1/4 SH-125 1 5/8 $ 14.87 

1 1/2 SH-150 1 7/8 $ 16.84 

1 3/4 SH-175 2 1/8 $ 18.82 

2 SH-200 2 3/8 $ 20.79 

2 1/4 SH-225 2 5/8 $ 22.77 

2 1/2 SH-250 2 7/8 $ 24.74 

2 3/4 SH-275 3 1/8 $ 26.72 

3 SH-300 3 3/8 $ 28.69 

3 1/4 SH-325 3 5/8 $ 30.64 

3 1/2 SH-350 3 7/8 $ 32.64 

3 3/4 SH-375 4 1/8 $ 34.61 

4 SH-400 4 3/8 $ 36.59 

● 4 ply silicone 

coolant hose 

reinforced with 

polyester fabric 

and coated with 

specially 

compounded 

silicone elastomer. 

● Continuous 

operating 

temperature -65ºF 

(-54ºC) to 350ºF 

(177ºC). 

● Resists 

chemicals, steam, 

ozone, coolants 

and aging 

conditions 

normally found in 

the engine 

environment. 

Reducers 

Size Part Number Each 

1.5 to 2 SR-150-200 $ 17.77 

2 to 2.5 SR-200-250 $ 19.37 

2 to 3 SR-200-300 $ 20.00 

2.5 to 3 SR-250-300 $ 20.00 

3 to 3.5 SR-300-350 $ 22.45 

3 to 4 SR-300-400 $ 24.25 

3.5 to 4 SR-350-400 $ 24.25 

Hump Hose 


2 HH-200 $ 17.43 

2 1/4 HH-225 $ 18.09 

2 1/2 HH-250 $ 18.73 

2 3/4 HH-275 $ 19.37 

3 HH-300 $ 20.00 

3 1/2 HH-350 $ 23.30 

4 HH-400 $ 27.14 


19

Adel Wiggins Flexible Tube Connectors 


Adel Wiggins Flexible Tube Connectors, or Wiggins Clamps, provide an ideal method for quickly and 

efficiently connecting and sealing two tubes. They are available in aluminum with a stainless two-finger latch, 

and are frequently used for vacuum lines, water lines, and turbo intake plumbing. All are qualified to AS1650 

and MIL-C-22263 specs., and are tested to greater than 125 psi. operating pressure, at temperatures up to 

450º F depending mainly on the o-ring material. 

Our Wiggins Coupling Assembly is 

comprised of one Clamshell Assembly 

(clamp and sleeve), and two Weld Ferrules. 

O-rings are not included. 

Sleeve 

Clamp 

Complete Coupling Assembly, minus O-rings 

Tube OD Part Number Wt. - lbs Assembly 

1/2 W991-8DE-050-A 0.054 $ 65.95 

5/8 W991-10DE-063-A 0.062 $ 72.35 

3/4 W991-12DE-075-A 0.075 $ 77.00 

1 W991-16DE-100-A 0.096 $ 83.50 

1 1/4 W991-20DE-125-A 0.112 $ 90.00 

1 1/2 W991-24DE-150-A 0.128 $ 123.10 

1 3/4 W991-28DE-175-A 0.146 $ 136.00 

2 W991-32DE-200-A 0.177 $ 140.25 

2 1/2 W991-40DE-250-A 0.209 $ 155.00 

3 W991-48DE-300-A 0.282 $ 172.45 

3 1/2 W991-56DE-350-A 0.338 $ 260.00 

4 W991-64DE-400-A 0.385 $ 327.00 

Weld 

Ferrule 

O-rings 

(not supplied) 

Weld 

Ferrule 

While Burns Stainless does not supply 

O-rings, Wiggins Clamps use industry 

standard O-rings, defined by the SAE. 

In the reference table below, the O-ring 

size code is AS568A followed by the dash 

number indicating the part’s dimensions. 

Tube Use O-ring Nominal Nominal 

OD AS568A- Inside dia. Cross section 

1/2 -015 9/16 1/16 

5/8 -017 11/16 1/16 

3/4 -117 13/16 3/32 

1 -214 1 1/8 

1 1/4 -218 1 1/4 1/8 

1 1/2 -222 1 1/2 1/8 

1 3/4 -224 1 3/4 1/8 

2 -226 2 1/8 

2 1/2 -230 2 1/2 1/8 

3 -234 3 1/8 

3 1/2 -238 3 1/2 1/8 

4 -242 4 1/8 

Clamshell Assembly 

(clamp with sleeve) 

Tube OD Part Number Wt. - lbs Each 

1/2 W991-8DE-050 0.034 $ 39.45 

5/8 W991-10DE-063 0.038 $ 43.35 

3/4 W991-12DE-075 0.043 $ 46.00 

1 W991-16DE-100 0.052 $ 48.00 

1 1/4 W991-20DE-125 0.058 $ 48.00 

1 1/2 W991-24DE-150 0.062 $ 52.00 

1 3/4 W991-28DE-175 0.07 $ 58.00 

2 W991-32DE-200 0.083 $ 62.25 

2 1/2 W991-40DE-250 0.097 $ 77.00 

3 W991-48DE-300 0.144 $ 94.45 

3 1/2 W991-56DE-350 0.176 $ 160.00 

4 W991-64DE-400 0.201 $ 215.00 

Weld Ferrule ( 2 required per connection ) 

Tube OD Part Number Wt. - lbs Each 

1/2 W903B8D-050 0.01 $ 13.25 

5/8 W903B10D-063 0.012 $ 14.50 

3/4 W903B12D-075 0.016 $ 15.50 

1 W903B16D-100 0.022 $ 17.75 

1 1/4 W903B20D-125 0.027 $ 21.00 

1 1/2 W903B24D-150 0.033 $ 35.55 

1 3/4 W903B28D-175 0.038 $ 39.00 

2 W903B32D-200 0.047 $ 39.00 

2 1/2 W903B40D-250 0.056 $ 39.00 

3 W903B48D-300 0.069 $ 39.00 

3 1/2 W903B56D-350 0.081 $ 50.00 

4 W903B64D-400 0.092 $ 56.00 

Common O-ring materials are Buna-N, Viton, and Silicone. 

If you don’t have a source for O-rings, McMaster Carr (www.macmastercarr.com) maintains a large stock. 

For tech info on the internet, see www.marcorubber.com, www.afmusa.com or www.pspglobal.com. 

20 


Turbo Inlet, Downpipe and Wastegate Flanges, 3-Bolt Flanges, Head Flanges 

Turbo Inlet Flanges 

T3 and T4 Turbo Inlet Flanges - CNC Machined 304 Stainless 


ID Height ID Width Bolt Center Bolt Center Tang. Flange 

Type Part Number (A) (B) Width (C) Height (D) Port Width (E) Thickness Each 

T03 T3F-RECT-304 1.94 2.31 3.40 1.75 N/A 3/8” $ 43.55 

T04 T4F-RECT-304 1.94 2.94 3.25 2.75 N/A 1/2” $ 55.02 

T04 Tangential (1.88”) T4T-188-304 2.06 N/A 3.25 2.75 1.45” 1/2” $ 65.00 

T04 Tangential (2.00”) T4T-200-304 2.15 N/A 3.25 2.75 1.52” 1/2” $ 65.00 

T100 (88-106mm) T100-RECT-304 2.45 3.65 4.45 2.75 N/A 1/2” $ 67.05 

C 

B 

Downpipe Flanges 

Type Part Number Each 

HKS 100mm 3” DPF-HKS-300-304 $ 57.42 

T04 Rnd 2.75” DPF-T4-275-304 $ 72.92 

T04 Rnd 3” DPF-T4-300-304 $ 72.92 

A 

E 

D 

Wastegate Flanges 

Type Part Number Each 

Deltagate WDF-150-304 $ 26.50 

Racegate WRF-175-304 $ 27.00 

Our turbo flanges are CNC machined inside and out, with a generous chamfer on the outside edge. 

Downpipe flanges are 1/2” thick. Wastegate flanges are 3/8” thick. 

3 Bolt Flanges - 304 Stainless, CNC Machined 

These high quality flanges 

are CNC machined from 

3/8 thick, 304 stainless plate. 

With a 3/32 chamfer all around 

the perimeter, they look good 

and are nice to your knuckles. 

Head Flanges for Race Applications 

3 Bolt Flanges 304 Stainless 


2 3BF-200-304 $ 34.50 

2 1/4 3BF-225-304 $ 34.50 

2 1/2 3BF-250-304 $ 38.25 

3 3BF-300-304 $ 40.75 

3 1/2 3BF-350-304 $ 47.50 

CNC machined from 3/8” mild steel to resist warping. Recommended for stainless and mild steel headers 

1 7/8", 18 degree Chev V-8, individual flanges 

Part Number 

Price per set 

CHF-188-1 $ 95.00 

Set includes 2 center flanges 

and 4 outside flanges 

1 7/8" SB-2 Chev V-8, square port, 4 port flange 

Part Number 

Price per set 

CHF-188-2 $ 95.00 

Set includes 2 flanges 

1 3/4" Ford/Yates V-8, square port, individual flanges 

Part Number 

Price per set 

FHF-175-1 $ 95.00 

Set includes 8 

individual flanges 


21

Collector Tabs, O2 Rings, Header Bolts, Solar Flux, and TIG Welding Rod 

U-Bracket, Straight Overlapping A-B, and Cast Stainless Lug-Style Tabs 

● Precision stamped and 

formed from 304 Stainless. 

● Light-weight design looks good 

and resists warping and breaking. 

● 5/16" Hole diameter. 

U-Bracket Tabs 

Each 

304 Stainless $ 2.50 

● Fabricated from .109” thick mild steel 

or 304 stainless, to align and affix the 

collector slips to your header tubes. 

● Step heights of .156 ( Type “A” ) 

or .094 ( Type “B” ). 

A-B Tabs 

Each 

Mild Steel $ 1.88 


Part Number Centerline Bolt Height Length Bolt Size Each 

Cast Lug 0.52 0.6 1/4 $9.00 

Cast Lug 2A 0.36 0.7 1/4 $9.00 

Cast Lug 2B 0.31 0.7 1/4 $9.00 

A 

● Cast 304 Stainless tabs provide robust slip 

tube fastening. 

● .600" long, with clearance hole for 

1/4"screws. 

B 

Cast Lug 1 Cast Lug 2 

● O2 Sensor Rings are precision 

machined 304 stainless with 

18mm x 1.5 thread to fit standard 

Bosch-type Lambda sensors. 

● Mild Steel Plugs for O2 rings 

come with a thick copper washer. 

O2 Sensor Rings and Plugs 

O2 Sensor Rings 

Each 


Plug for O2 ring 

Each 

Mild Steel $ 5.00 

304 Stainless Header Bolts 

not 

shown 

Stainless 12 point, shouldered 

header bolts - 3/4” long 

Header Bolts - Stainless Part Number Each 

5/16-18, 3/4 long HB-75-312SS $ 1.90 

3/8-16, 3/4 long HB-75-375SS $ 1.90 

Pipe Bungs & Nipples, Solar Flux, and Welding Rod 

1/2" Pipe Nipple, 45º angle cut $ 12.50 each 

1/8 Pipe Bung - 304 Stainless $ 2.95 each 

TIG Welding Rod 

Type Diameter Price / lb. 

308, 309, 347 SS .035 $23.50 

5356 Aluminum .062 $14.00 

Titanium .035 call 

Inconel 625 .030 call 

Solar Flux is perfect for welding 

all stainless and alloy steels. 

It takes the place of inert gas 

inside the tube. 

1 lb. can $ 39.95 

22 

Burns Stainless LLC 949.631.5120 Monday - Friday 7:30 am to 4 pm fax 949.631.3184 burnsstainless.com


UltraLight Stainless Motorsports Mufflers 

Burns Stainless UltraLight Stainless Race Mufflers 

offer the greatest value in a race muffler available to the motorsports community. 

● Remarkably light-weight 

● Extremely durable 

● Built to the highest quality standards. 

● 100% stainless construction 

● Completely TIG welded 

● Easily replaceable aerospace ceramic muffling cartridge* 

● Inside diameters from 2” all the way to 5” 

● Can be built to custom length (call for quote) 

● Optional Stainless scrubble packing available (call for quote) 

If you need the highest performance and the lightest weight 

race muffler you can get, at a price you can afford, here it is. 

UltraLight Stainless Mufflers 

Inlet dia. Part Number Case dia. Length Wt. Lbs. Each 

2 SM-200-450-14 4 1/2 14.00 2.96 $ 212.05 

2 1/4 SM-225-450-14 4 1/2 14.00 2.9 $ 213.69 

2 1/2 SM-250-350-12 3 1/2 12.00 1.87 $ 192.77 

2 1/2 SM-250-350-17 3 1/2 17.13 2.61 $ 216.75 

2 1/2 SM-250-450-17 4 1/2 17.13 3.56 $ 229.40 

3 SM-300-450-12 4 1/2 12.00 2.4 $ 190.12 

3 SM-300-450-17 4 1/2 17.13 3.53 $ 228.52 

3 1/2 SM-350-450-6 4 1/2 12.00 2.3 $ 243.16 

3 1/2 SM-350-450-12 4 1/2 17.13 3.23 $ 213.11 

3 1/2 SM-350-450-17 4 1/2 17.13 3.23 $ 230.27 

4 SM-400-550-6 5 1/2 12.00 2.8 $ 253.66 

4 SM-400-550-9 5 1/2 17.13 4 $ 206.86 

4 SM-400-550-12 5 1/2 17.13 4 $ 223.98 

4 SM-400-550-17 5 1/2 17.13 4 $ 242.27 

4 1/2 SM-450-600-6 6 9.75 2.57 $ 253.66 

4 1/2 SM-450-600-9 6 15.00 4.38 $ 223.59 

4 1/2 SM-450-600-15 6 15.00 4.38 $ 246.67 

5 SM-500-600-6 6 12.00 3.65 $ 260.08 

5 SM-500-600-9 6 12.00 3.65 $ 213.30 

5 SM-500-600-12 6 12.00 3.65 $ 230.51 

5 SM-500-600-17 6 12.00 3.65 $ 253.44 

* Optional Stainless scrubble packing available - please call for price 


23

BurnSonic TM DR-1 Lightweight Collector Muffler 

Burns Stainless offers a lightweight racing collector muffler just for drag racers. 

This innovative design, featuring an integral merge collector and a space saving wedge profile with unique 

oval outlet, incorporates 25 years of racing exhaust system design experience. 

Extensive dynamometer testing of this muffler on a Super Stock Chevrolet Big Block drag racing engine 

has demonstrated no loss of torque or power as compared with our latest technology Reverse-Cone 

Megaphone exhaust system. It has yielded similar stellar results on other premier drag engines, producing 

over 1250 horsepower. 

Track sound measurements have shown that the muffler meets 

or exceeds the NHRA 95 dB requirement for applications tested. 

Each muffler is custom-designed to match your engine using our 

X-design parametric computer software, insuring the highest performance. 

PRODUCT HIGHLIGHTS 

● High-temperature carbon fiber and stainless steel construction 

for lightweight and longevity. 

● Professional race quality, 100% purge, TIG-welded construction 

for extra strength. 

● Stainless steel collector is extensively hand polished in the 

Burns Stainless tradition producing better flow characteristics 

and more power. 

● Internal perforated core is designed and formed to maximize 

flow performance and reduce sound. 

● Innovative high temperature ceramic and Monel packing for 

increased sound deadening and reliability. 

● Modular design allows for repair and re-packing by Burns 

Stainless. 

● Low profile design will fit most V-8 drag race configurations 

including full bodied vehicles. 

● Light-weight design reduces stress on header mounting 

● Easy 'slip-on' installation. 

● 'Pan-evac' fittings available. 

● 4 into 1 configuration only. 

Price quoted on request. 

Patent Number D406,089 

other patents pending 

24 


Stainless Steel 

Stainless steel is a material that we wish never was labeled 

"stainless" because it can do so much more than simply resist 

rust. The origins of stainless steel date back to the early 

1900s when an English metallurgist developed a type of steel 

for making knives that would not rust. Technically, "Stainless 

Steel" is strictly a trade name applied to what are known as 

corrosion-resistant steels. It is a fabulous material that 

outperforms mild and alloy steels in so many different 

applications in racing that no other material can match it, and 

I think all racers should consider it as a vital element in their 

fabricating efforts. However, stainless steel does have some 

unique properties that the fabricator needs to know about 

before launching into a project. An interesting characteristic 

of many types of stainless steel is that they are nonmagnetic, 

a quality that makes them very important in the 

aerospace industry. Compared to mild steel, stainless steel 

has superior high temperature characteristics. It is an 

excellent material for headers and exhaust systems, or any 

application where high heat is encountered. 

Stainless steel is similar to mild and alloy steels; it is an alloy 

of iron that contains at least 12% chromium. This high 

chromium content retards corrosion giving the steel its 

"stainless" quality. There are many alloys of stainless steel, 

which are broken down into two basic categories: 

1. Chromium-nickel grades 

2. Straight chromium grades 

The chromium-nickel grades are the more common stainless 

steels used in race car fabrication compared to the straight 

chromium types, due to the nickel content which provides 

excellent weldability and corrosion resistance. Also, this 

nickel improves some mechanical properties such as fatigue 

strength, toughness and ductility. People sometimes refer to 

stainless steels based on their chromium and nickel content: 

for instance, 18-8 stainless has 18% chromium and 8% nickel 

in it. 

Stainless steel typically has a rather low carbon content, in 

the range of .08% to .15%, and sometimes as low as .03%. 

The carbon is needed for hardness, but it also can cause the 

stainless to become susceptible to corrosion at high 

temperatures. What happens is this: when chromium-nickel 

steel is heated to a temperature range of 800° to 1590°F, the 

carbon in the steel combines with chromium to form 

chromium carbides. This transformation is called carbide 

precipitation and reduces the corrosion resistance of the 

steel. The chromium is reduced in this heat-affected area and 

makes the steel subject to what is known as intergranular 

corrosion. Some stainless steels are known as low carbon 

grades to minimize this carbide precipitation; others, such as 

321, are special alloys that reduce carbide precipitation by 

combining and stabilizing the chromium at elevated 

temperatures. 

You have probably heard Smokey Yunick talk about 

maintaining high exhaust velocity and increase scavenging by 

covering headers with a thermal wrap. In addition, there are 

companies that coat headers with a thermal barrier, typically 

some type of ceramic formula, in order to keep the heat 

inside the exhaust system. Stainless steel performs this 

function without the need for add-ons because it has a much 

lower coefficient of thermal conductivity, thereby keeping 

more heat inside and transmitting it to the header outlet. 

Radiated heat is perhaps the most important reason to wrap 

or ceramic coat the headers to protect the car and the driver 

from excessive, fatiguing high temperatures. 

Typical 1010 carbon (mild) steel conducts 219% more heat 

per foot than do the types of stainless steel we use in header 

fabrication. By contrast, quite a bit more heat stays inside 

the stainless header tubes and does not get passed into the 

surrounding air. By not allowing the contraction of the cooling 

gases as they flow down the tubes, more exhaust velocity is 

retained which promotes better scavenging at the collector. 

This retention of velocity increases the overall header 

efficiency. 

You've probably seen Indy cars with their enclosed engine 

compartments and thermal clam-shell enclosures around 

their turbocharger headers. They must thermally wrap their 

exhaust pipes just so the radiant heat off the tubes won't 

cause fires or melt any critical systems. In this case headers 

made out of mild steel would completely fail and break apart 

due to the severe heat retention, let alone scale and send 

death particles into the turbocharger, ruining the turbine 

blades. 321 stainless steel has excellent high temperature 

fatigue resistance in this enclosed application and does a 

darn good job of living in this hostile environment better than 

any other material except the ultra-high nickel content steels 

(such an Inconel), which are hard to find, very difficult to 

work with and extremely expensive. 

These many characteristics, such as superior heat retention 

properties, high temperature fatigue resistance, and to a 

lesser extent, the cosmetic value of a non-rusting finish, 

combine to make stainless steel an ideal choice for headers 


25

Stainless Steel 

and exhaust systems. Such a system will produce more 

horsepower and last "'til the cows come home". It is an 

excellent solution. 

Now that you are sold on the merits of stainless steel, there 

are a number of things you need to know about the different 

types available before you launch into a header and exhaust 

system project. 

A three-digit numerical classification system is used 

throughout the industry. The racer needs to be familiar with 

only one of these three-digit series within the system - the 

300 series. They offer the fabricator a wide array of choices, 

from ornamental quality up through the highest-temperature 

and closest-tolerance aircraft quality. 

Within the 300 series of stainless steels, there are four types 

that are suitable, available and cost effective for the racer. 

These are 304, 316L, 321, and 347. 

321 and 347 are known as stabilized grades of stainless. 

These are alloyed with either titanium (321) or columbium 

(347), both of which have a much stronger affinity for 

carbon than does chromium at elevated temperatures. 

This eliminates carbide precipitation leaving the chromium 

where it belongs for corrosion protection...remember our 

discussion of intergranular corrosion? Both 321 and 347 

are top choices for exhaust headers, especially 

turbocharger systems and rotary engines. Since 321 is 

much more available than 347, that leaves 321 as the first 

choice, with no sacrifice in needed qualities. 

316L is an extra low carbon (ELC) grade of stainless that 

has only .03% carbon, making less carbon available to 

precipitate with the chromium. It is used extensively in 

marine exhausts where salt water corrosion mixed with 

diesel exhaust particulates and electrolysis create such a 

hostile environment that even other grades of stainless 

have difficulty coping with it. 

sizes, pipe may sometimes be substituted for tubing, and 

vice versa. Numerous wall thicknesses are available, but for 

headers, normally .049" ( 18 gage ) to .065" ( 16 gage ) is 

used. 

Different specifications are used to meet particular 

requirements for the military (MIL), the American Society of 

Testing Materials (ASTM), and the Society of Automotive 

Engineers (SAE). Examples of what to look for when you 

order stainless tubing are as follows: 

ASTM A-554 304 stainless is a welded mechanical tubing 

used primarily for ornamental purposes. It is not fully 

annealed and is work-hardened slightly in manufacturing. It 

has good column strength and good bendability. 

ASTM A-269 304 stainless is a general service commercial 

specification that is higher quality and is fully annealed for 

better ductility. It is available in both welded seam and 

seamless, and is a good spec for the racer to use. We have 

not seen any difference in longevity between welded seam 

and seamless stainless tubing in header use, but there is a 

substantial cost difference. The column strength is not as 

good as A-554, but it has excellent bendability with a 

higher cost due to the full annealing. 

MIL-T-8808/8606\MIL-T-6737 321 stainless are military 

specifications for aircraft tubing. Suffice it to say that some 

MIL-specs are not necessarily better or even as good as 

some ASTM standards. There is no particular magic here. 

There are as many uses for stainless steel as there are 

projects in the shop. I can think of nothing else that transmits 

an image of quality and skill to the majority of fabricators 

than a cleanly constructed stainless steel project. Whether it 

be a set of headers, intake stacks, or even a stand for one's 

dyno engine cooling fan, stainless steel has such great 

mechanical properties that its use should be considered for 

many projects beyond exhaust systems. 

304 is the most inexpensive and available stainless in the 

300 series. It is suitable for normally-aspirated header 

applications, and has been successfully used by many 

racing teams. It does not have the high temperature fatigue 

resistance that 321 does, but is considerably less costly 

and much more available. Most 304 tubing these days has 

the dual designation of 304/304L. 

Practically speaking, there are overlapping applications of 

304 and 321 stainless in header construction, but knowing 

you've got the insurance of the aircraft-grade 321 for the job 

is definitely worth consideration despite the extra cost..if 

your application requires it. 

Stainless steels come in both tubing and pipe sizes. Since 

certain pipe sizes are almost identical in dimension to tubing 

26 


Inconel® 

Inconel refers to a family of trademarked high strength 

austenitic nickel-chromium-iron alloys that have 

exceptional anti-corrosion and heat-resistance properties. 

These alloys contain high levels of nickel and can be 

thought of as super-stainless steels. Inconel alloys are 

used for a variety of extreme applications including navy 

boat exhaust ducts, submarine propulsion motors, 

undersea cable sheathing, heat exchanger tubing and gas 

turbine shroud rings. For many years, Inconel has been 

used for Formula One and Champ 

Car exhaust systems. More 

recently, several Winston Cup 

racing teams have utilized Inconel 

for producing ultra-light, highdurability 

exhaust headers. 

Burns Stainless recommends 

Inconel 625 alloy for exhaust 

systems due to its excellent 

strength, corrosion resistance and 

fabricability. This alloy also exhibits 

high creep and rupture strength; 

outstanding fatigue and thermalfatigue 

strength; as well as 

excellent weldability (though the guy welding it might have 

a different opinion!). Inconel 625 contains molybdenum 

and columbium, which stiffens and strengthens the nickelchromium 

matrix without precipitation hardening 

treatments. Some hardening however does occur when 

heated to intermediate temperatures (1200 F to 1600 F) 

increasing room temperature strength. Also, this alloy 

retains over 75% of its room temperature strength at 1200 

F. This alloy is available in a wide variety of forms including 

tubing, sheet, bar, plates and castings. Burns Stainless 

typically stocks welded and drawn Inconel 625 tubing. The 

tubing specification is SAE AMS 5581, Nickel Alloy, 

Corrosion and Heat Resistant, Seamless or Welded 

Tubing. 

Inconel 625 can be welded using conventional stainless 

steel TIG welding techniques. Inconel Filler Metal 625 rod 

is used to weld Inconel to Inconel as well as to dissimilar 

metals including stainless steel. Inconel weldments are 

high strength and are highly resistant to corrosion and 

Typical 

Formula 1 

Inconel 

Headers 

oxidation. Many welders describe welding Inconel as 

"dirty". In other words, the weld pool appears to be under a 

"skin" and is not well defined. In addition, the weld pool is 

somewhat "sluggish" as compared with steel or stainless 

steel. These characteristics tend to result in a "coarse" 

appearing weldment as compared to stainless steel. 

Welding Inconel is not necessarily more difficult to weld 

than stainless, just different. By following the welding 

procedures outlined in the header construction tips article 

on burnsstainless.com, successful welds with Inconel 625 

are possible. 

A BMW F1 engine lights up its Inconel pipes 

Formula 1 Ferrari Inconel periscope 


27

Aluminum 

Aluminum is widely used in racing to make anything from 

radiators to pistons to intake manifolds (However, we 

would never recommend aluminum for exhaust systems!). 

The properties of aluminum that make it so attractive to 

racers include light weight, strength, fabricability and 

corrosion resistance. Aluminum is approximately 1/3 the 

weight of steel, yet some aluminum alloys exhibit tensile 

strengths greater than some low carbon steels. Many 

alloys can be heat treated to improve strength properties. 

Aluminum is available in many wrought forms such as 

tubing, extruded shapes, sheet and bar. Aluminum can 

also be cast using a variety of foundry methods using 

moderate strength heat treatable alloys. Forging can also 

be used to form aluminum. This material can be fastened 

with rivets, bolts, or welding. Welded fabrications can also 

be heat treated. 

There is a variety of wrought and cast alloys available for 

use by the racing fabricator. Adding alloying elements to 

enhance the physical properties of aluminum for specific 

purposes creates these alloys. Wrought aluminum alloys 

are designated using a four-digit system, with the first digit 

specifying the alloying element. The following table lists 

the major series including the alloying elements and 

general uses for each series. 

Some of the more common aluminum alloys used by racing 

fabricators include 3003, 2024, 6061 and 7075. 3003 is a 

non-heat-treatable wrought-alloy, which has excellent 

workability and weldability and is used for low-strength 

applications including tanks, boxes and brackets. 2024 is 

a heat-treatable, high-strength alloy with limited 

formability and is not weldable. It is an excellent choice for 

chassis skins and spars and for flywheels. 7075 is heattreatable 

and the strongest and stiffest of the commonly 

available aluminum alloys. Due to its strength, it is not 

readily formable and lends itself to be used for machined 

components and straight suspension pieces. 7075 also 

has poor welding characteristics. 

6061 is the least expensive and most versatile of the heattreatable 

alloys. It is a favorite alloy of many fabricators 

as it is a weldable alloy with moderate to high strength in 

tempered condition. It also has good formability in the 

annealed condition. It is the best choice for intake 

manifold and inter-cooler plumbing due to the weldability 

and formability of the alloy. 356 aluminum is an excellent 

weldable, heat-treatable casting alloy. It is used for a 

Alloy 

Series 

Major Alloying 

Elements 

General Properties 

General Uses 

1xxx 

None 

Excellent corrosion resistance, high thermal and 

electrical conductivities, low mechanical 

properties, excellent workability 

Chemical Equipment, reflectors, heat 

exchangers, electrical conductors 

2xxx 

Copper 

Heat treatable, high strength to weight ratio, 

limited corrosion resistance, limited weldabilty 

Truck wheels, truck suspension 

components, aircraft fuselage 

3xxx 

Manganese 

Moderate strength without heat treating 

Beverage cans, cooking utensils, heat 

exchangers, storage tank 

4xxx 

Silicon 

Low thermal expansion, high wear resistance 

Forged engine pistons, welding rod, 

brazing alloys, architectural products 

5xxx 

Magnesium 

Good weldability, good corrosion resistance 

Ornamental trim, cans, household 

appliances, boats and ships 

6xxx 

Magnesium and Silicon 

Heat treatable, good formability, moderatestrength, 

good weldability, good machinability, 

good corrosion resistance 

Architectural applications, bridge railings, 

welded structures, racecar components 

7xxx 

Zinc 

Heat treatable, moderate to very high strength 

Airframe structures, high-strength forgings 

8xxx 

Other elements 

N/A 

N/A 

9xxx 

Unused series 

N/A 

N/A 

28 


variety of applications including pump housings, 

transmission cases, cylinder blocks. 

As previously mentioned, heat-treating improves the 

strength of aluminum alloys through a process known as 

"precipitation hardening." In simple terms, precipitation 

hardening is a process that occurs during the heating and 

cooling of an aluminum alloy in which minute particles or 

"precipitates" are formed in the aluminum matrix. These 

particles reduce slippage between "grains" which in turns 

increases material hardness and strength. 

The chemistry involved varies with each particular alloy. 

However, in basic 

terms, when an 

aluminum alloy is 

heated for a 

certain amount of 

time above its 

" s o l u t i o n 

temperature," the 

alloying elements 

dissolve uniformly 

into the aluminum 

matrix. Following a 

quench (or rapid 

cooling), the 

alloying elements 

will slowly fall out 

of solution and 

combine with each 

other to form 

evenly distributed 

precipitates. This 

step, known as 

aging, occurs at room temperature, however, and alloy can 

be artificially aged at an elevated temperature in order to 

speed up the process. 

Another method for increasing the strength of aluminum 

alloys is by work hardening. Work hardening occurs during 

forming processes including forging, stamping and tube 

bending. During these forming processes, the alloy 

undergoes plastic deformation and the metallic grains are 

broken and become smaller. The tighter grain structure 

prevents inter-granular slippage thereby increasing the 

strength of the alloy. 

Annealing is a process that imparts the "softest" or most 

ductile condition to a heat-treatable aluminum alloy. For 

annealing, the alloy is heated to above its solution 

temperature and then slowly cooled to room temperature. 

During the cooling processes, the alloying elements fall out 

of solution and form large unevenly distributed crystals, 

which do not effectively prevent granular slippage. The 

result is a soft, low strength alloy condition. Burns 

Stainless anneals all aluminum tubing prior to bending. 

The temper designation system is used to specify the 

condition, or temper, of a heat treatable alloy. The most 

common designations include O (sometimes erroneously 

referred to as TO), F, T4 and T6. O refers to soft or 

annealed condition and is the preferred temper for forming 

processes such as tube bending. F refers to the condition 

of the material following a forming process during which 

work hardening occurs, and is the official designation of 

tubing bends. T4 designates that the alloy was solution 

heat treated and 

naturally aged. T6 

is sometimes 

referred to as fully 

"heat treated" and 

is the result of 

solution heat 

treating and 

artificial aging. 

Burns Stainless 

carries only drawn 

seamless 6061 

aluminum tubing 

for straight tubing 

and bends. The 

tubing specification 

is ASTM B-210 

and/or Federal 

G e n e r a l 

Specification WW- 

T-700/6. This 

tubing is manufactured by cold drawing a true seamless 

extruded tube made from hollow extrusion ingot processed 

by die and mandrel extrusion process. Straight 6061 

aluminum tubing available from Burns Stainless is sold in 

the T6 condition. It is important to note that welding will 

effect the temper of a tube since it locally heats up the 

metal. If the strength of a T6 temper is necessary for your 

welded assembly, it is important that the assembly be heat 

treated. It is also important to note that the aluminum 

bends are annealed and through the bending process 

achieve a certain level of work hardening. Again, if heat 

treated properties are required, the assembly must be heat 

treated. 


Aluminum 

Burns Stainless recommends extra care when polishing 

aluminum in the O condition, because the softness of the 

material tends to make it pick up and gouge if the polishing 

medium is not kept extremely clean. 

29

Reference Tables 

Wire Gage (BWG) to Decimal Inches 

Gage inches Gage inches Gage inches Gage inches 

28 .014 20 .035 12 .109 4 .238 

27 .016 19 .042 11 .120 3 .259 

26 .018 18 .049 10 .134 2 .284 

25 .020 17 .058 9 .148 1 .300 

24 .022 16 .065 8 .165 0 .340 

23 .025 15 .072 7 .180 00 .380 

22 .028 14 .083 6 .203 000 .425 

21 .032 13 .095 5 .220 0000 .454 

Properties of Metals Used in Motorsports Applications 

Material Property 

Units 

Aluminum 

6061 “0” 

condition 

Aluminum 

6061-T6 

Mild Steel 

1010 

CREW 

304 


Annealed 

ASTM A269 

321 


Annealed 

Titanium CP- 

2 Grade 2 

ASTM B 

338 

Inconel 

625 

Tensile Strength 

lb/in 2 (@70 F) 

18,000 

45,000 

55,000 

85,000 

90,000 

50,000 

140,000 

Yield Strength 

lb/in 2 (@70 F) 

8,000 

40,000 

40,000 

35,000 

35,000 

40,000 

77,000 

Elongation 

percent 

25 

12 

20 

55 

55 

20 

47 

Density 

lb/in 3 

0.098 

0.098 

0.283 

0.290 

0.290 

0.163 

0.305 

Modulus of Elasticity 

x 10 6 lb/in 2 

10 

10 

29.5 

28 

28 

15 

30 

Coefficient of Thermal Expansion 

in/in-F x 10 -6 (@70 F) 

13.1 

13.1 

7.228 

9.9 

9.6 

4.8 

5.5 

Coefficient of Thermal Conductivity 

BTU/ft-hr-F (@70F) 104.00 96.50 26.98 9.40 9.30 12.00 5.65 

30 


Reference Tables 

Fraction to Decimal conversion 

Fraction inches Fraction inches Fraction inches Fraction inches 

1/4 .250 1/2 .500 3/4 .750 

1/64 .016 17/64 .266 33/64 .516 49/64 .766 

1/32 .031 9/32 .281 17/32 .531 25/32 .781 

3/64 .047 19/64 .297 35/64 .547 51/64 .797 

1/16 .063 5/16 .313 9/16 .563 13/16 .813 

5/64 .078 21/64 .328 37/64 .578 53/64 .828 

3/32 .094 11/32 .344 19/32 .594 27/32 .844 

7/64 .109 23/64 .359 39/64 .609 55/64 .859 

1/8 .125 3/8 .375 5/8 .625 7/8 .875 

9/64 .141 25/64 .391 41/64 .641 57/64 .891 

5/32 .156 13/32 .406 21/32 .656 29/32 .906 

11/64 .172 27/64 .422 43/64 .672 59/64 .922 

3/16 .188 7/16 .438 11/16 .688 15/16 .938 

13/64 .203 29/64 .453 45/64 .703 61/64 .953 

7/32 .219 15/32 .469 23/32 .719 31/32 .969 

15/64 .234 31/64 .484 47/64 .734 63/64 .984 

Welding Rod Compatibility Table 

Aluminum Mild Steel 

Aluminum 5356 1 or 4043 2 

Mild Steel 

X 

304 SS 

Note 1: maximum strength 

Note 2: maximum corrosion resistance 

X - not recommended 

304 SS 321 SS Titanium CP-2 Inconel 625 

X 

X 

X 

X 

309 

309 

X 

625 

308 

308 

X 

625 

321 SS 

347 

Titanium CP-2 

X 

CP Grade 2 

Inconel 625 

625 

X 

625 


31

Race Engine Specification Form 

Name 

Address 

City & Zip code 

Country 

Vehicle and type of racing 

Engine manufacturer 

Useable RPM range 

Maximum RPM 

Peak horsepower @ rpm 

Peak torque @ rpm 

Displacement 

Bore 

Stroke 

Compression ratio 

Cylinder head manufacturer 

# of camshafts & location 

Valves / cylinder 

Manifold type 

Intake valve head diameter 

Exhaust valve head dia. 

Company 

Phone 

Fax 

Email 

Racing class or category 

Configuration / # cylinders 

Kind of gain you want 

If your’e able to send a copy of a current dyno sheet, 

flow data, or information abstract, please do so. 

Additional comments: 

Cylinder head model 

Type of fuel system 

Carburetor or throttle size 

Intake port dimensions 

Exhaust port dimensions 

Cam manufacturer & model # 

Intake lift at valve 

Int. duration @ .050 lift 

Intake opens @ 

Exhaust lift at valve 

Exh. duration @ .050 lift 

Exhaust opens @ 

degrees* 

o BTDC 

degrees* 

o BBDC 

Lifter type (roller, flat, hyd.) 

Intake rocker arm ratio 

Intake lobe centerline 

Intake closes @ 

Exhaust rocker arm ratio 

Exhaust lobe centerline 

Exhaust closes @ 

* if duration @ .050 is unknown, specify lift at which it is measured 

Header Configuration ( 4-1, tri-y, etc ) 

Primary length 

Primary OD (or step diameters) 

Step lengths 

Secondary length 

Secondary OD 

Step lengths 

Collector outlet diameter 

Collector type 

Tailpipe diameter 

o ABDC 

o ATDC 

32 


Burns Stainless Caps, T-shirts, and Sweatshirts 

Caps - 

$15 

each 

T-shirts - 

$17 

each 

FlexFit, black with red piping around the bill. 

Burns Stainless logo embroidered on the front, 

and burnsstainless.com embroidered on the back. 

Available in S/M and L/XL sizes. 

Black, 100% cotton crew neck, short sleeve. 

Silk-screened Burns Stainless logo on left front 

and right sleeve. Header/collector/megaphone 

graphic on back. M, L, XL, and XXL sizes. 

Sweatshirts - 

$28 

each 

Black crew neck, long sleeve, cotton/polyester blend 

with embroidered Burns Stainless logo on the front, 

and burnsstainless.com embroidery on the back. 

M, L, XL, and XXL sizes. 

Terms and Conditions 

Shipping 

Order Size 

Pricing 

Payment 

Credit 

Warranty 

Returns 

We ship by United Parcel Service (UPS) C.O.D., or you can charge orders to Mastercard, Visa, American Express, or Discover. 

If charging to a credit card, we need to know the name on the card, the account number, the type of card (Mastercard, Visa, 

American Express, or Discover), and the expiration date of the card. All orders will be shipped F.O.B. Costa Mesa, California, U.S.A. 

The cost to process an order, regardless of size, is about the same. Our minimum order is $25.00 

As some of our products are affected by the changing price of metals, we reserve the right to change pricing at any time and 

without prior notice. Quantity pricing is available - please call for details. 

Money order or cashiers check until your company check application has cleared. 

When your application is approved your company check will be accepted. 

Credit is subject to managementís approval. Until a charge account is established, all shipments will be on a C.O.D. or 

credit card basis. All credit privileges are subject to a periodic review. Past due accounts will forfeit open account privileges. 

Since our products are intended for racing we offer or imply no warranty. 

All returns must have a return authorization number (RA#). Returns without the RA# clearly marked on the package will be refused. 

All returns must be freight prepaid; any freight collect shipments will be refused. All returns are subject to a 20% restocking fee. 

Thank you for your business. We appreciate it.

Burns Stainless LLC 

1013 West 18th Street 

Costa Mesa, CA 92627t 

Presorted 

Standard 

U. S. Postage 

Paid 

Costa Mesa, CA 

Permit #4353

Burns Catalog 2005xxxxxx.qxd - Visiter le site web de l'utilisateur ...

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?