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View Full Version : De-Webbing Td5 exhaust manifold.



landy
29th March 2015, 04:34 PM
I got around to de-webbing the exhaust manifold today. Once I made the initial cut I simply knocked out the 5mm blocks i made. I attempted to file the edges flat but quite frankly it was to hard work so it was off to Bunnings this morning.
I bought a High speed burr for the die grinder. I've been meaning to get a good quality one for years but never needed one so badly to warrant the cost. So once home cranked up the compressor and set about the Manifold.
I wish i'd spent the money years ago. That burr just cut though the cast iron like a hot knife though butter. It made short work of the job and well worth the $60 outlay.
You can clearly see the amount that the manifold has warped in the photos. No wonder it snapped the stud. I don't know how it didn't pull out both studs.

DazzaTD5
29th March 2015, 10:08 PM
Good tidy job.
Thats not the worst I've had, about 4mm is the worst!

One added thing I do is we have a jig for the milling machine is to run it over and get all the flanges back on the same plane (actually you can do the inner 3 a few thou under). Any half decent machine shop should be able to do that for you

Because you cant bend that cast back to the head correctly.
The short explanation to the warped manifolds is the castings are still green when put into service (then cure and warp in service) hence why not all TD5 engines suffer it. There are countless engines over the years that have all suffered the same issue.

Regards
Daz

Blknight.aus
29th March 2015, 10:56 PM
one the first one snaps you get some torsional relief onto the second one.