exhaust manifold problem

[wengr]

Iv'e been having problems with valve guide seals I got in a complete gasket kit. Now I see that the ex manifold to headpipe gasket is also inncorrect. It has holes for four studs, however my manifold has 6 studs. is this the proper manifold(6 stud) for a US spec 83? Vendor no help so far.Do I have the wrong gasket kit or a previously swapped manifold/head?

[So Cal Mark]

that manifold doesn't use a gasket

[wengr]

ahh well that would explain it. many thanks

[narfire]

That manifold looks like a canidate for the "nut and weld method" to remove any broken studs.

[htchevyii]

Ya I had the same problem, it had been so long I assumed that I had lost or thrown away the old gasket and the fact that the gasket set came with one further confused the issue, but six studs= no gasket. Good luck with those studs, the weld a nut does work well.

[wengr]

I've miged a few nuts on them so far, but no luck. the weld or the stud still breaks before they turn. So I'm treating them with penetrating oil for a while and will try again.

[wengr]

I've miged a few nuts on them so far, but no luck. the weld or the stud still breaks before they turn. So I'm treating them with penetrating oil for a while and will try again.

tried again with the weld method with no luck. In this case it is impossible to get a weld that is stronger than the stud to manifold bond. and this is after alot of penetrating oil. So out come the drill bits.

[spider2081]

Not sure but if there are any you can drill from the back side, sometimes a stud will come out as you drill. Another thing to try is to purchase left twist drill bits and put the drill in reverse. The same thing is accomplished. Sometimes the stud will come out as you drill. Course in this economy you might find it cost effective to take the manifold to a local machine shop and see what they want to remove the studs and clean the surface for you.

[racydave]

Thoes studs are not going to come out. Not on a exhaust manifold. Best thing is some of the holes could be held with a longer bolt and nut. Have you a good set of drill bits?

[manoa matt]

Why not just drill them completely out and all the way through. Then use stainless steel through bolts

[wengr]

Success. after drilling with successively larger bits, trying my best to keep it straight and centered, I got them to the point where they could be tapped. Using antisieze and brass nuts for the future. So for the cost bits, taps, and studs that equals or more the cost of a used manifold, it's done and hopefully they'll hold. I like the idea of preserving the part, and I'm stubborn so they were coming out one way or another.""

[manoa matt]

Ahh, I see some of them can't be drilled all the way through. Good job, it looks great. If you are so inclined some ultra high temp copper RTV liquid gasket will seal up the mating surfaces.

[wengr]

thanks for the tip on the sealant, I think I'll try it. must be tough stuff to hold up on an exhaust manifold. This manifold really wanted to retired for an Allison header, but alas no $$ so back on it goes.