Precision Flatten Manifold Flanges with only Hand Tools
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- Опубліковано 8 вер 2024
- In this Episode I Demonstrate a Method of Precision Flattening Warped Manifold Flanges, with only Hand Tools.
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Good teaching this is a unknown art to most people I am a self taught ( mostly) machine rebuilder I have used this very same technique to resurface hardened ways on vmcs when they couldn’t be taken down or moved for grinding I have found a cut off wheel works well allows some flex, also good to use a stone between spotting cycles to remove any burrs that may have been produced from the grinding to protect your surface plate. Great work!
When I trued up a welded angle plate, I pretty much did the same thing. I didn't figure I'd find someone else showing it off. I found that I liked to use a well-worn flap disc instead of the hard grinding wheels. The cuts are shallower and the flexibility of the disc kind of lets you tap/bounce from spot to spot. Made the final passes a lot faster.
Also, if you're stuck in BFE trying to make a repair this way, the hardest thing to find might be a flat reference surface. You may be able to use the mating surface (e.g. the exhaust face on the head) if you can get the studs out. That way it's ground to match (which is ultimately what's needed), even if the mating surface itself isn't flat. I've used a similar technique with a die grinder and shim stock to make a fitted shim to go between surfaces that had worn against each other until they were both out of dimension and out of flat.
Thanks. Interesting and imaginative use of an ancient technique I would not have considered until now.
Cheers Don.
Love your techniques and thank you for sharing this process and the thinking behind it. What a ripper teacher!
Thanks Mate, Cheers.
Thank you, Thank you, Thank you!!! I've been sitting on a pair of stainless power V8 long tube headers for a 6.2L Ford Raptor for the past year because of warped flanges. I didn't want to spend the money for a machine shop to surface them and I had yet to come up with a good DIY remedy. After finding this video the other day, I bought a thick piece of glass plate for $15 US dollars, a tube of permatex prussian blue and started the process exactly as you showed. Very time consuming but it's kinda relaxing and more importantly it's working. From how it's going, I expect to be within 1 to 2 thousands of an inch over 16 1/2", if not better.
Glad you found it helpful Mate, this method has helped me out many, many times. Quite time consuming as you say, but I too find things like this very therapeutic & at least the reward is there at the end. Cheers.
How’d it go
And hold up
@@KollynJ great, Haven't had any problems with the gaskets or leakes
Thanks for sharing the secret! It came in just in time as well, I am about to take the warped headers off my project car and will definitely try this out.
How did it work any tips
@@KollynJ It worked quite well. The car is up and running since and as far as I can tell no exhaust leaks. If I only had one advice to give it would be to go slow. Removing material is easy, putting it back on not as much. I chickened out on the angle grinder and opted for 2 inch sanding disks instead. Slow but works. Good luck.
Thanks for the run down. I have a shop, large manual mill and all but for the life of me could not find a reasonable way to hold the manifold in the mill. Will go this route
Mate, totally with you there. Can't beat a Mill, but Christ its hard to hold awkward stuff sometimes. Cheers.
Going to try this on a 1970's cast iron tractor manifold.
She's not too fussy :)
Thanks for sharing, saved me a couple hundred dollars to spend on other parts needed
Thank you for taking the time to demonstrate this technique.
My Pleasure Mate, hope you find it useful. Cheers.
Exhaust manifold on my '89 toyota pickup was warped by 0.5mm. Had some trouble getting the finishing touches with the grinder but a sheet of sandpaper on the table smoothed out the rest real quick. A fresher flap disc woulda helped but I just worked with what I had. Thanks for sharing
Great Stuff. Cheers Mate.
Great flattening method, thanks for sharing!
Cheers Klass
Very nice! So nice that I'm convinced that the gasket will be "optional". Cheers!
Certainly Doable, Cheers Mate.😃
I’m thinking about just building up a ring around the port with the flux or stick. One port is .05 shallow the 2nd port in may be .02
Sweet!. As a knifemaker I discovered a nice thick tempered glass shelf from bunnings was cheap and extremely effective for me
I've just gone on their site & had a look, sweet, might get myself one of those. Thanks for the tip. Cheers.
hi mark can you send me the link to the glass thanks
@@captaincook3693 this one is slightly different to the one I have which I can't find on the website but basically the same except mine has a slight curve on one side. 800mm x 200m x 8mm toughened glass 👍 www.bunnings.com.au/flexi-storage-800-x-200-x-8mm-clear-glass-shelf_p2580924
@@markhingst5368 Thanks Mark
Brilliant thanks for the tip.
Happy to help, Cheers Mate.
I'd buy one off you for my 95 3cyl Geo. Man that's exactly what I need for my fender exit.
Another brilliant video mate. Very interesting, thanks. 👍
Cheers Stephen.
Before I got my surface plate, I would use our granite kitchen counter top for laying out wet and dry paper on to flatten surfaces. Needless to say, the wife was not impressed with this method.
No, they're not happy when you bring "Man Stuff" into the Kitchen Hey. I have been guilty of using both the Oven & Dishwasher for non conventional kitchen activity you might say.
Cheers.
surprised that works...thought you were crazy when you said grinder lol
G'day, lets give it a tosser name - how about 'Rotary Scraping'. Cheers, Steve (Perth)
Sounds good to me Steve, Cheers Mate.
Make a stand with adjustable studs that can bolt to the holes around the ports you aren't grinding on . And fits in your vise to keep it from moving
Thats a Great Idea James, Cheers Mate.
Far cheaper than a surface grinder, much cheaper than a Biax scraper, but it obviously requires practice. I have watched Russian machine rebuilders do the same on lathe ways. Very instructive. Thanks!
Thanks for dropping by Juan, Cheers.
Great video, can you please demonstrate some siphoning techniques for water or fuel? Thank you
Well done
Thanks Mate.
Single flange in stainless will warp on first use. Nice clamping plate, could have used individual flanges with that stout header.
The idea of a single piece flange goes back to thin, long tube headers where the flange was an assembly aide. When using short Schedule 10S stainless, individual flanges are a better idea.
My turbo manifold is very warped,Im going to try this as engineering shops want hundreds.
Good Luck with it Mate, you'll do fine.
@@TheAussieShed I called granite bench shops,glaziers left messages no one was interested so I bought a $30 combination square from bunnings, bearing blue and got it pretty close in about an hr.Close enough so it doesnt puff out and fail the car safety checks .Its $190 for a surface block big enough here in NZ thanks for the tips! It had about 1mm rock end to end !
Awesome trick cheers
Glad you liked it, Cheers.
subscribed from the uk :-)
Thanks Graham, Cheers.
Anyone have any tips for using this method or reasons not to do it?
Great job, poor mans milling machine !
Cheers David.
This is brilliant! Been putting off flattening my turbo manifolds flanges for years because I couldn't think of a way to do it. Can you use finger belt sander (or whatever you call it) for more accuracy, or will you go through a tonne of sanding belts?
BTW, the turbo manifold is for my nuclear-powered destructomobile, which I will use to take over the world. But I will be a benevolent leader. Does this count as using my new-found power for good?
G'day Mate, finger sander would probably work great, give it a go & report back. A+ on the powers for good. Cheers.
@@TheAussieShed Can't believe it's been 6 months already! I used your method to remove the concave-ness from my turbo flange. Then I used a hand-held belt sander to get it completely flat. It got the flange totally flat lengthways, but somehow made the flange concave in widthways, ie in the shorter direction. I don't even understand how it could do that! :'-(
Now I'm contemplating whether to buy a new manifold (complicated because I'll have to add an external wastegate flange), attempt to flatten it again somehow, or to chop the flange off and weld a new one - but then that would have to be flattened afterwards anyway. :( :(
Excellent. Away with the grinder on my new GT3 pipe flanges that are like a banana. I hope there was nothing crucial between the first 5 minutes and the last 2 minutes of the video.😜
No, sounds like you're all good Mate. Cheers.
at aboutn18:00, why aren't you removing material from the right side ?
I wanted to understand this as well. I think he stuck to the middle because it was levering in the middle and that’s what was keeping the other side up
if you apply the blue way thicker it will be flat a lot sooner....
Interesting method. Why don't you use a hand file instead of a grinding wheel? Should make it less wavy
G'day Mate, files are good for edges but not this type of thing. If done correctly it is the opposite of Wavy. Biggest drawback of this method is it is slow. Cheers.
6 people couldn't figure out how to turn on the grinder they bought.
G'day Mark, yep, its the "Dunning-Kruger" effect at work I reckon. I've done many, many, Exhaust Manifolds & Flanges this way with 100% success rate. Some people seem to struggle with the fact that a lot can be achieved with hard work & some smarts. Cheers Mate, thanks for the comment.
Hi if you interested in building turbo Manifolds hot cide cold side piping for good amount of money I’m interested 350z 370Z your work is art
Hi Ali, wish I had the Time Mate, but thanks for the offer, much appreciated.
Cheers.
👍😎👍