Just scored a TD5 exhaust manifold how to clean

[PhilipA]

I just scored a second hand TD5 exhaust manifold which I intend to elongate the holes, maybe remove /modify the webs, have machined flat and have ceramic coated.
My question is how to get it cleaned enough so that it can be coated inside and out and any tips on say how many MM to elongate the outside holes and inner holes, and any other general tips.
Regards Philip A

[discorevy]

I use the foaming oven cleaner that you can get in the supermarket, find it works great, although the ceramic coating shop will prep it to their requirments ,as for the holes , just leave number 3 and drill the rest out to 10 mm , along with de webbing , it won't warp or shear studs again even with a heavy fuel map.

[Xtreme]

IMHO the only way to elongate the holes effectively is to do it by fitting to the vehicle that it is going to eventually end up on and note where it is binding on the studs. Remove and drill/file/elongate each hole to ensure equal clearance on each stud. You will undoubtedly need to carry out this procedure numerous times until you achieve the desired clearance/s.

[Tins]

As for cleaning it, don't bother, the guys who coat it will take care of that. They throw it in a bath of something. The one I took them was dirty and rusty, now it's very pretty.

[davidjanssen88]

I'm removing my egr next week and plan to just use a solvent to clean it. I think one of the members posted the LR part # in an old thread/

Part # STC9713

[wozapinin]

Forgive me for butting in on this post. I also have an exhaust manifold that needs sorting. I live in woop woop so need to send it to someone who can sort it for me, ie elongate the holes, re face and ceramic coat. Can someone put me onto someone (who knows what they're doing) who would do this for me...cheers.

[PhilipA]

So today I got up enough get go to work on the manifold.

So I took out the ribs by cutting down them in sections with an electric hacksaw, drilling the base of each section, then just snapping them off with a pair of channel grips.
Then I ground the mess flat to eliminate all of the saw marks so no stress risers.
I then got into the holes and elongated the outer 1-5 and inner 2-4 inwards, so that if the manifold expanded it had room to move.

I then took it down to my favourite engineering shop to straighten up. It will be there a week.
I have ordered a set of Wurth Mercedes studs from UK which come with nuts and sold as a TD5 kit on ebay., and supposed to be much stronger than LR ones.

I have to just organise some washers now and then have the manifold ceramic coated..
Regards Philip A