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Headers from Hell!
For those of you that have ever owned your own business, you may identify with this little story quite well. If you have intentions of starting your own venture, this just might stop you dead in your tracks!
Roughly four years ago, we recognized the need to perfect some higher horse- power headers for both the 944 and 928 kits. We had an existing design that worked well for the 928 auto, but it was never adapted to fit the manual trans cars. For the 944, two or three sets were hand built to test a design, but we didn't see the need to invest in a production run of 10 sets at the time.
Then came the sudden increase in popularity to both conversion kits! We thought, now we had better have an answer for our customers that had big HP on their minds and in their budgets!
Since we were happy with the 944 headers, we saved up a few bucks and decided to concentrate on those first. The gentleman that was building the one-off headers did an excellent job and I looked forward to any time spent visiting his shop. Upon arrival one evening, I asked for a set of headers I ordered a few weeks previous, and he went to go retrieve them. He returned empty handed with a rather distraught look on his face. I asked, "What happened?" He said the last set I picked up was the only set he had, they were the "example" set. I asked about a jig. "What jig?" was his answer. Apparently he built the headers one at a time copying the example set. Oops?
I tried to beg for a set back from a few customers, but they had them bolted to their running cars already. Pictures were OK, but since the amount of room was very sparse, we basically had to start from scratch to be exact.
Meanwhile, we made sure there was a jig built for the Auto 928 headers and then we attempted to find someone to fabricate a test set for the manual model as well. This began a-two-year-long waste-of-time through three different, highly regarded, header magicians, all located in Southern California. Numerous trips, tons of calls, harsh words, and a whole host of other problems yielded NOTHING but lost time and money.
Back to the 944 headers. We currently have, as most of you know, a very compact and effective set of block-hugger headers for the 944 V-8 conversions. These are great up to about 400 HP. We have sold lots of these with terrific success. Our old design, as mentioned (and lost) above, was good up to about 450 HP but was not easily installed. Since 500 HP has become the benchmark for an affordable motor, streetable power (kinda), yet untouchable by any production built ride, we really needed to design and build the "final" set of high horse power 944 headers. Back to trying out header guys?
This time we decided to look in the Mid West for one of the "finest header builders around!" so our contacts said. We were lucky enough to have a very good friend, and an excellent fabricator, develop a custom 944 design that we were quite sure would work. So we contracted this header builder to make magic out of metal. One month, two months, three months, nothing. A few calls, nothing. Another month, another 10 calls, nothing. Was the check cashed? Yep. Hmmmmmm. So we asked this friend to stop by the shop and see what was up. We, unfortunately, found that the header guy was nearly killed in a drag strip accident. Well, that was a very tragic bit of news, but we were given a promise that the headers would still be done very soon.
Another two months went by and I didn't want to pressure the guy, but it was time to start the calls again. After calling every day for about a month, I started calling the other businesses he had linked on his site. I actually got lucky and talked to the owner of the property he rents. She assured me a message would get to him.
When I finally got a call the next day, the header guy said he was back in the hospital for another month. Well, what do you say to a man that was spending weeks at a time eating lousy food, feeling like hamburger? I understood and once again acknowledged his need for a bit more time. He, once again, promised a week, and that turned into another month.
Well, the good news, we finally got the headers. The bad news, they wouldn't fit if you had a 10 pound sledge hammer and a jar of Vaseline.
Back to the 928 headers... We have had a hollowed out shell of a 928 sitting around here in hopes we might build a "Silver State Classic" car some day, but that is another story you don't want to hear. It has, however, come in handy for different little projects.
This time, after about 2 years of attempting what seemed to be the impossible, we begged a very trusted old friend and master machinist here in Vegas to build some headers for the 928. Very reluctantly he agreed, knowing just how hard it is to build them correctly. With the 928 shell of a car rolled into his shop, and a block and heads bolted in place for fitment, he started the task at hand. Back and fourth from his shop to ours, he tried and tried. Well, not only did he get it he nailed it!
We had a production ready set of 928 headers that fit both the auto and the manual cars. In addition, they were roughly equal length, tuned to within about an inch, and over 21 inches long total!!! This was the most beautiful set of headers I had ever seen (for more reasons than one)!
We began marketing the new headers and we struck up a deal with our header guy to build the jig. He put off the jig building for other pending projects until we started selling a few sets. In a panic to fill our very quick orders, he started building copies without the use of a jig, swearing each set would be the last set until a jig was built. Then his world came crashing down with the tragic death of his business partner and best friend. No more headers. Again, what do you say to a guy who just lost his best buddy? Back to the drawing board.
944 headers again... We made friends with a custom car builder and a very knowledgeable customer of ours out of Florida. Our exchange of information has been terrific to say the least. He had been following the whole header development saga for some time and he wanted a crack at it. Instead of trying to build something half a world away, we took him up on his suggestion to come to Vegas and bend and weld some tube. Without any offence meant to anyone, what I saw over the next week was frustration x 10. His "Medusa" as he called it, was not meant for the weak stomached individual. With his tail held firmly between his legs, he admitted defeat and left promising a new design in a week or two. Well, that was about 2 months ago, and we have yet to see anything from his camp.
One night, my partner Mike, got so pissed off with the whole header thing, that he started to weld tube together seemingly at random. With a 944 on the lift with an LT-4 installed, a complete motor on a stand with straight plugs, and several examples of what not to do near by, he began the impossible. Two days later (about 32 hours total) he had completed a miracle! The 944 headers were built and they worked perfectly. Without a moment to loose, the jigs were built to match every curve, every line, every angle, and the first production set are nearing completion as we speak. Yes, we officially have 944 headers!
And finally, back to the 928 headers. We managed to get one final set of 928 headers from our local machinist and we have kept them for ourselves. They currently live on Mike's 928 and are performing flawlessly. Since pulling a motor is not difficult for us, we figure we will pull Mike's motor when we finally find someone to build these custom headers. We don't have any sold at the moment, so Mike continues to enjoy his car knowing it could be motorless if his partner sells another set!
As you can see we are just like many of you, trying to make ends meet. Someone accused us of living lavishly, making tons of money, and selling inferior parts. Well, I assure you, we lavish in our happiness because we enjoy what we do. We make just enough to pay our staff a wage, keep the lights on, and the dinner table served. And, damn-it, we sell parts that work, period.
I appreciate your time reading this little story. I hope it gave you some insight on just what it has taken to get Renegade to this point of very respectable success. This was just one example of many trials we have endured? and trust me, there have been lots! Please feel free to give us a call if you have any additional questions. Thank you for your interest in Renegade Hybrids!
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UPDATE
If you don't believe prayers are answered, this one made a believer out of me. The above-mentioned "Header Story" was written back in early 2004. Since then, a very talented young welder named Daniel walked through our door. With a state welding championship trophy to prove his abilities, he is making jewelry from junk and now working at Renegade. With the 928 headers really increasing in popularity, and the 944 LT-1 (and now the 944 LS-1) headers selling even faster, we can afford his talents! Here is just a little quick snap shot of the new LS-1 headers built by Daniel, coated, and ready for sale! ( picture )
Again, thanks for reading our little story. I am sure we will have many more in the future!
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