1956 Ford F100 - Totally Tubular

After making the four wire forms, No Limit's founder began to build the fourth header tube (counting from right to left on the passenger side). He realized the short piece should be 5/8 inch from the transition tube.

Better than SWAG (smart wise-ass guess), Rob used the Hawaiian "hang loose" hand sign to measure how long the next piece of header pipe should be.

He marked the 1 5/8-inch-diameter tube for cutting.

With the pipe held firmly in the vise, the Milwaukee reciprocating saw went through the new steel swiftly.

By marking where the tack-welds should be, he can weld the two tubes at the proper angle.

Prior to tack-welding, the No Limit engineer confirmed the two pieces fit the TIG aluminum-wire template.

On the workbench Rob tack-welded tube No. 4 together. After approximately 11 inches, each header tube steps up from 1 5/8-inch diameter to 1 3/4-inch diameter. Welding two different-diameter tubes together prevents exhaust reversion, as there's a built-in barrier (step) within each header tube.

Since the header tubes would be coming back off the flange for the final weld, Rob lightly tack-welded tube No. 4 on the flange. He continued the fabrication process on the passenger side...

...meanwhile, Mike laid down finish TIG welds on each driver-side header tube.