broken manifold

[The ho har's]

yes i have broken a 101 right hand exhaust manifold at the exhaust pipe end between the studs don't known if welding will hold has anyone got a spare :angel:



mrs HH to post photos

Harry

[harry]

poo bum !!!

i have seen some wonderful welded repairs to cast exhaust manifolds, but always suspect them.
can it take a manifold from a 3.5 or 3.9 disco?
i suppose the heads are pretty similar.

[Blknight.aus]

I thought the headers were the same as the 3.5 and it was the y pipes that changed....

if they are I think I have a set on an old motor that Im being indecisive about what Im doing with it.

[harry]

dave, maybe type in the p/n in the big aus mil computer,
they might still hold stock!

[bee utey]

yes i have broken a 101 right hand exhaust manifold at the exhaust pipe end between the studs don't known if welding will hold has anyone got a spare :angel:



mrs HH to post photos

Harry


My old neighbour was a whizz at this sort of thing, he used to heat the manifold and weld it with stainless steel rods on a stick welder. He was a true old time self taught engineer....

[Lotz-A-Landies]

I gave Iain Reed a pair of repaired 101 manifolds when he bought the engine, he may part with one. But a better option may be to find a pair of manifolds off a P38 which breathe better than the original 101 manifolds.

Pretty much work like extractors in the limited space of the 101s engine bay.

[The ho har's]

the manifold is one off due too chassis rail being so close as i understand

harry

[101 Ron]

RHS manifold is extremely hard to find.......I dont think you will find one.
Think of it being made of glass too........extremely brittle.
LHS is advailible and is the one that usually cracks.
On the LHS you have little option other than a 101 manifold.
On the RHS some other manifolds will fit , but the out let will be pointing downwards towards the front diff and not towards the rear.
A rover P38 RHS will fit with extensive rework of the exhaust system and a harder to get MG 3.5 V8 manifold.
Fitting another manifold type will cause problems with the wiring and control cables running along the RHS of the chassis and motor.
Repair may be the simplest option and would be best done with brazing or cast iron filler and TIG welding with preheating and post heating treatment.
Breakage of the RHS manifold is normally caused by some one swinging on the back of the manifold trying to undo the exhaust flange bolts or a poorly secured or in flexable exhaust system.
Ron

[PeterP]

Hi Harry,

Definite bummer about the exhaust. This would be my first port of call and the best chance in OZ - Anthony Johnson, British 4WD Imports Pty Ltd, (03) 9728 8046. Email: british4wd@bigpond.com

I recently saw pictures of a set of hand made headers for the 101, they looked the goods. Pics must have been on the 101club forum. Had a quick look but cannot find them but will keep looking.
I like the sound of Rons repair suggestion as the quickest fix.
Peter

[chazza]

Cast iron welding is not difficult, if as Ron says the part is pre-heated and post-heated.

I put the parts in a charcoal brazier with all the pre-welding prep already done and the parts tacked together. Just before the cast iron gets to dull red heat, whip it out of the fire onto the welding table and complete the weld. Weldall rods from BOC work well. Immediately after the weld is completed, return it to the heat, cover it with coals and allow it to cool slowly.

For extended welding times it will be necessary to return it to the heat more than once, before the welding can be finished,

Cheers Charlie

[Lotz-A-Landies]

Hi Harry,

Definite bummer about the exhaust. This would be my first port of call and the best chance in OZ - Anthony Johnson, British 4WD Imports Pty Ltd, (03) 9728 8046. Email: british4wd@bigpond.com

That was the source of the repaired manifolds I had. He couldn't help with undamaged ones, but still worth the call.

Diana

[Mick_Marsh]

I read on the 101 site this morning that a P6 manifild will fit the RHS.

[101 Ron]

On the RHS there are options, but like I said it is still a bit of work to get it all sorted as the manifold will be closer to the cables and wiring running on the RHS of the motor and the manifold oulet will be in a totally different spot to the original one.
The LHS is a real problem........even the professionally made ones to suit the 101 need the chassis thinned out (cut and reworked) 1/2 inch to make it fit......just like the 101 forum one.
Thats why the 10s exhaust manifolds are cast, so they are compact and why they tend to be abit restrictive .
AJ did have the LHS new.

[The ho har's]

Thanks to everyone i just welded it looks good,the big test will be doing the nuts up on the exhaust :D


harry

[101RRS]

Each time I have tinkered with my exhaust I have busted a manifold - they are so brittle - I have kept the broken ones to be brased up if needed later.

Luckily I got one left and one right one with my 101 when I bought it but have used them now. I believe normal V8 manifolds can be used but this means rebuilding the exhaust pipe to take it further forward and under the sides of the engine.

Not totally sure of this so do your own research but I believe P38 4.6 headers exist the rear of the engine like the 101s do and certainly fit on the right hand side. Not sure about the left side and have heard different stories. One is that they fit straight on and the other is that the inside top edge of the chassis needs to cut out and a new piece welded in to provide the clearance.

The other option is to make a manifold from scratch out of the same material that extractors are made out of - there are no complicated bends just welding so that is always an option if you have a template.

Garry

[The ho har's]

Pics hh said I would put up:)

Mrs hh:angel:

[DasLandRoverMan]

When I rebuilt my old GS it got a set of stainless tubular manifolds from an MGB V8 fitted, the left hand one went in with oodles of space, whilst the right hand needed a bit taking out of the engine mounting (not enough to worry about) with the downpipes reworked to put the Y pipe where I wanted it.

I was pretty happy with how it all went together, but nearly £500 for the manifolds, downpipes and Y was kinda steep.

A mate of mine had recently had the same problem, he reworked a P38 one to fit the 101 system.

[101 Ron]

I was talking to AJ today.
He has repaired exhaust manifolds in stock.

[The ho har's]

hh welded it and is and on and works:D

Does anyone use spring washers instead of the locking tabs??

The camera battery was flat so hh wanted to fit it to see if he was successful with the welding, so pour quality pic.

Mrs hh:angel:

[101RRS]

hh welded it and is and on and works:D



I would not be crowing just yet - if it holds up after a decent offroad trip then all will be good.

Garry

[lardy]

dont you just get some extractors made?
or modify some headers from a p38 ?

[101 Ron]

dont you just get some extractors made?
or modify some headers from a p38 ?

Its just not that simple..........go a fit some other headers/ manifolds especically on the LHS and you will find out why.

[The ho har's]

I would not be crowing just yet - if it holds up after a decent offroad trip then all will be good.

Garry

Yes exactly, that is why we are taking 'herc' on the weekend trip with the GCLRO series vehicle run to see if it holds up:) and if so down for the NSW run:)

Mrs hh:angel:

[The ho har's]

Repeating the question...


Does anyone use spring washers instead of the locking tabs??


Mrs hh:angel:

[101 Ron]

WhenI replaced my manifold I reused the locking tabs.

If using spring washers I would try and get some stainless steel items as they will take the heat better without losing there bite.

[The ho har's]

I have gone for s/s flat washers

a ten km drive so far all is well ;)

Harry

[iain reed]

hi
yes i have some if you want them sorry for the delay been ofline
deep in the work thing, let me know what you want an i can post them up to you

:):):)

[The ho har's]

hi
yes i have some if you want them sorry for the delay been ofline
deep in the work thing, let me know what you want an i can post them up to you

:):):)

Thanks Iain,

We have a club run this weekend so we will see if it holds:) If not it will be a noisy weekend:D

you coming to the 'across the border' camp out??

We hopefully will be in the 101:D

Cheers
C

[Ratel10mm]

Well? How'd it go?? All good I hope? :)

[The ho har's]

Well? How'd it go?? All good I hope? :)


It held:D ran sweet all weekend, we did about 250k's of mountains and back roads, but our fridge died, will ring you;):)

Mrs hh:angel:

[Ratel10mm]

Glad it held. :) I'm planning to do the maintenances local to you between tomorrow & Wed. Although they may get pushed to Fri. depending on callouts, so at this stage whatever day suits you after work. :)

[The ho har's]

Glad it held. :) I'm planning to do the maintenances local to you between tomorrow & Wed. Although they may get pushed to Fri. depending on callouts, so at this stage whatever day suits you after work. :)

Any afternoon after about 3 I will be here;) besides Thursday:)

Mrs hh:angel:

[iain reed]

good to hear let me know if you need the manifolds :):)

[The ho har's]

well we have just completed around 2,000km run to Coolah and back and it held:D So hopefully all is well from now on:)

Ohh and 'herc' behaved well except for the rear axel seal leaking, which i managed to fix by reworking the spring, got spares just in case but didn't need them, for now;)

hh