Exhaust Manifold

[dobboy 231 2 Cars]

What's the correct tools/method to get this thing off?

 

I'm struggling to get 3 nuts off in the centre, and fear I may have or will end up rounding them.

 

TIA

[welshpug 1,678]

6 sided socket and a short extension bar or a deep socket.

 

if all else fails, irwin nutgrips.

[Slo 283 1 Cars]

If you've got any thread sticking out of the nut you could tighten another onto it giving something better to undo it but dont overdo it

[dobboy 231 2 Cars]

Thanks guys,

 

When my nuckles have stopped bleeding I'll give it another shot.

 

Welsh, I'm sure my deep sockets were too long, mines are about 80mm long.

 

Great idea Slo!

 

Although I have visions of me with a hacksaw blade with a rag wrapped around it cutting the nuts off.

[Slo 283 1 Cars]

Sod that get a dremmel on it lol

[dobboy 231 2 Cars]

Is there any reason they used the softest nuts they could find at the most awkward place on the engine? Is it for heat expansion? Or to stop the nut and bold welding together or something?

 

If I was an exhaust fitter I'd take a holiday if I saw a gti6 coming in!

[dobboy 231 2 Cars]

Got it off tonight without any problems.

 

I hit it last night with penetrating spray, so maybe that helped. Also taking the heat shield off made a big difference.... Doh

 

Thanks, another job done.

[dobboy 231 2 Cars]

I've gave the fabricator my manifold and explained where to cut etc, is the thickness of a standard cutting blade sufficient to get the new angle?

 

Not sure what blade thickness he's using, but I know it's a 6" blade......anyone know the likelihood of it being sufficient without further grinding?

[dobboy 231 2 Cars]

Does this look about right?

 

[Slo 283 1 Cars]

what on earth are you asking? is this one of those bodges where you cut a slit out bend it round and weld it back up?

Edited January 19, 2014 by Slo

[dobboy 231 2 Cars]

Slo, is that not how it's meant to be done?

 

If not, what is?

 

5hit.....

[stu8v 68 1 Cars]

My manifold fits with no mods.

 

I used part of the Xsara downpipe, then made my own system out of stainless.

[dobboy 231 2 Cars]

Thanks stu. I thought the majority needed mods to it, and that I would likely need it.

[welshpug 1,678]

yup, that's exactly what you need to do, best bet now is to bolt it to the engine, get the engine in the bay, bend the manifold till its sitting nicely then tack it in place, remove and weld up fully.

[dobboy 231 2 Cars]

Welsh, is there any reason why it can't be welded prior to it going in the car? Or is it so it only gets bent enough, and no more?

 

Also when on the engine and in the car, can it be taken off/put on easily enough? Or does the engine have to come out to put on/get off?

 

TIA

[harryskid 193]

Miles sells these and they are done really well, Good price too saves all that messing about!

[stu8v 68 1 Cars]

It saves even more by not doing it as you don't need to do it at all.......

[welshpug 1,678]

So what did you do then stu, bash the bulkhead?

Tilt the engine?

[stu8v 68 1 Cars]

Nope, Xsara manifold and short section of down pipe :-)

[jamie_1992 66 1 Cars]

thats how i did mine just took the gamble on how much to bend it and it paid off

i just used a normal cutting disc on a big grinder

[dobboy 231 2 Cars]

Nope, Xsara manifold and short section of down pipe :-)

So is the Xsara manifold slightly different?

[dobboy 231 2 Cars]

thats how i did mine just took the gamble on how much to bend it and it paid off

i just used a normal cutting disc on a big grinder

Thanks Jamie. That was my plan. Did you dress the welds inside the pipes? If so can you remember what you used?

[allye 530 3 Cars]

what on earth are you asking? is this one of those bodges where you cut a slit out bend it round and weld it back up?

All those high powered gti6 engines using this method on the exhaust. Oh what a bodge.....

 

It's not as black and white as saying you don't need to do it. We all know the tolerances between one shell and the next. I would always reangle it as even with this done the bulkhead wants right up. I could stick my foot up behind the dash whilst driving and feel how warm it was, and my bulkhead was covered in heat reflective material in the bay.

[Slo 283 1 Cars]

Well it is a bodge, i had to use this method on my own. Just couldn't see how anyone could judge that photo and say yes that's enough gap now bend it weld it up and the angle will be spot on when he hasn't even put any engine in his car yet.

[allye 530 3 Cars]

In that respect yes you won't get it spot on unless you're very lucky. But there is nothing wrong with the actual process of cutting and welding.

Edited January 20, 2014 by allye