Thread: td5 exhaust manifold , grinding out the web.

This might help... There is some good stuff on overseas forums also.

http://www.aulro.com/afvb/technical-...ification.html

Cheers

Here ya go.

TD5 Manifold Modification


And here:

Originally Posted by Pedro_The_Swift

Although partially iterating here's my recommendations after having done several manifolds

-If warped first cut webbing then enlarge stud holes (except those for centre cylinder), and only then reface (if needed that is)
-Replace all studs
-Use Class 8.8 or stronger studs (alloy steel, quenched and tempered)
-Smear with copper based anti-seize compound
-If using longer studs DO NOT screw all the way in (see how they come installed from factory)

Modified exhaust manifold after a high temperature paint treat:

EDIT ~ Looks like Josh_WA is on the ball.

Hello bob10

I did straight cuts(about 5 mm wide) through the webbing with a hack-saw from the face edge back towards the manifold. I then knocked the teeth that had been formed out with a hammer. I then hand filed(with 1/2 round files) what was left to a smooth finish.
A little time consuming but neat, and you do what you have to with available tools.
I then took the manifold to engine reconditioners and had the manifold refaced.

Cheers,

Jason

I had both no1 studs broken and one on no5. I have just done mine, I had the manifold refaced and I drilled the stud holes about 1mm larger except for number 3. Did not remove webbing, will see how it lasts.

Originally Posted by bob10

Could any of you good people point me in the right direction as to the procedure for relieving the stress in the exhaust manifold by grinding away the web. I know I have seen this on here somewhere, but can't seem to find it again [ probably looking me in the face]. Have to replace the dreaded broken stud , may as well do the other whilst I'm at it ,Thank you ,Bob. [ finally feel like a real Disco owner, ]

You don't have to go to the effort of completely grinding out the webs between the exhaust outlets on the manifold .....albeit it does make for a cleaner and more professional looking job. As you rightfully point out - all you are doing is "relieving" the thermal stress between the webs preventing manifold warpage. This can be achieved by simply running a hacksaw between the webs as it does exactly the same job. Feel free of course to remove all of the casting material if you wish but it's quite labour intensive

Originally Posted by Jason789

Hello bob10

I did straight cuts(about 5 mm wide) through the webbing with a hack-saw from the face edge back towards the manifold. I then knocked the teeth that had been formed out with a hammer. I then hand filed(with 1/2 round files) what was left to a smooth finish.

We did pretty much the same, except used an angle grinder to make 4-5 cuts in each web. Then tapped out the teeth with a hammer, and cleaned up with an air powered die grinder.

Sheet of emery over a pane of glass, gives a nice smooth, even surface to clean up and level out the mating surface.

What size drill bit did you use on Cylinders 1,2,4,5 to enlarge the stud holes on the exhaust manifold?

Removed webbing on mine! Was not a bad process at all