Jet Ski Header Pipe

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Jet Ski Header Pipe

Full custom turbo header system engineered start to finish

Build Overview

This project started with a clear brief. Build a full turbo header system for a jet ski with equal length runners. No log manifold. No shortcuts.

The challenge was space. There was almost none. The gap between the engine and the hull left very little room to work with, while still needing to maintain equal lengths and proper flow.

We approached it as a design problem first.

The engine bay and hull were 3D scanned and brought into CAD. From there, the full header system was designed to fit the available space while keeping everything equal length. To simplify fabrication and maintain accuracy, the design was built entirely around 45 and 90 degree bends using off the shelf sections.

Once the design was finalised, we 3D printed a full prototype to test fitment. After confirming everything worked, we designed and printed alignment jigs to hold each runner in place during fabrication.

The final build combined multiple processes.

A custom CNC machined header flange was developed to smoothly transition from the engine port into the exhaust system. The collector was 3D printed in stainless steel to optimise flow and packaging. Everything was then TIG welded together into the final assembly.

To finish it off, the headers were heat wrapped and the hull was heat shielded to manage temperature in such a tight environment.

This project is a good example of how we work. Solve the problem in the design phase, then execute with precision.

From concept through to final product.

3D CAD design of custom jet ski turbo header system showing equal length runners and tight engine bay packaging
3D CAD design of custom exhaust manifold showing equal length runners and tight engine bay packaging
3D CAD design of high performance exhaust manifold with equal length runners optimised for tight packaging and flow efficiency
3D printed prototype of high performance exhaust manifold used to test fitment and validate design before final fabrication
Side view of high performance exhaust manifold showing extremely tight clearance between engine and surrounding components
Precision CNC machined exhaust flange designed to transition smoothly from engine port to header runners
Exhaust header runner tacked in place using 3D printed alignment jig to ensure accuracy and equal length positioning
Exhaust runner positioned and tacked within a custom 3D printed alignment tool to maintain precise fitment and consistency
Exhaust manifold runners aligned in a custom 3D printed jig ensuring precise positioning and equal length during fabrication
CNC machined flange with three exhaust runners tacked in place before final welding, showing initial manifold assembly alignment
Exhaust header runner being TIG welded with back purging to ensure clean internal welds and optimal flow performance
Stainless steel 3D printed exhaust collector welded to V-band flange, forming the outlet of the high performance manifold system
Fully assembled high performance exhaust manifold with equal length runners, stainless collector and V-band outlet ready for installation
Custom fabricated exhaust header system completed with TIG welded runners, CNC flange and 3D printed collector in a compact design
Final turbo exhaust manifold assembly showing equal length runners, precision welding and tight packaging for high performance applications

First Fire Up

Initial break in on low boost with base tune dialled in