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Author HOW TO: Make an exhaust flange
DaveyLC
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Registered: 8th Oct 08
Location: Berkshire
User status: Offline
5th Nov 08 at 23:24   View User's Profile U2U Member Reply With Quote
Probably of interest to nobody but I decided to take some photos and it might help anyone doing a conversion who wants to build their own exhaust components.

The first step is to find a piece of thick enough steel that is roughly the same size as the flange you wish to mate up to (sounds saucey) I'm using 5mm thick mild steel. Once you have the steel make a hole in the middle the same size as the original flange, in this case I am making a 2.25" hole:



Once you have the hole, align it with the original flange and mark up the outline and hole centers:


Drill the pilot holes or use a center punch, then drill the fixing holes:



Now you can cut off the excess steel with a thin disc cutter or even a hacksaw if you've got the patience; the easiest way by far is to use straight cuts to start with like so:


Once the waste material is removed you can tidy it up with a bench grinder or angle grinder.



And voila! Just need to weld it onto the down pipe now
BarnshaW
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Registered: 25th Oct 06
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5th Nov 08 at 23:25   View User's Profile U2U Member Reply With Quote
very nice mate and very nice manifold!
andyc1234
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Registered: 7th Nov 06
Location: Lancashire
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5th Nov 08 at 23:31   View User's Profile U2U Member Reply With Quote
plasma cutters are more fun
not a bad job anyays
andyc1234
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Registered: 7th Nov 06
Location: Lancashire
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5th Nov 08 at 23:31   View User's Profile U2U Member Reply With Quote
what engine is that manifold for ?
DaveyLC
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Registered: 8th Oct 08
Location: Berkshire
User status: Offline
5th Nov 08 at 23:32   View User's Profile U2U Member Reply With Quote
If only I had one lol..

Z18XE/X18XE1
broster
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Registered: 6th Dec 02
Location: Drives: E39
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6th Nov 08 at 07:15   View Garage View User's Profile U2U Member Reply With Quote
looks good, i find it far easier to get stuff laser cut, be amazed at the cost if you can supply a cad drawing ready for their machine.
Warren G
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Registered: 14th May 06
Location: Kent
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6th Nov 08 at 07:33   View User's Profile U2U Member Reply With Quote
all that work for a crap manifold
DaveyLC
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Registered: 8th Oct 08
Location: Berkshire
User status: Offline
6th Nov 08 at 08:59   View User's Profile U2U Member Reply With Quote
15 minute job

I was however at the workshop till 11pm doing my f**king braided hoses.. Had to make up new front lines because the old ones were siezed up a treat. ARGH!

 
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