Exhaust manifold problem and a question

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Originally Posted by clintooo

But I've gone out and bought 4 x m10 studs. So will pull off the manifold during the week and drill and tap N0.1 & No.5.

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Carefully. I believe the water jackets are in danger if you are a little overenthusiastic. I don't know this first hand, but so I was told. I measured the depth of the holes and put a collar on my drill, but you could probably feel when you bottom out.

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Originally Posted by clintooo

Does anyone have any tips for how to drill out the gasket without destroying it. I was thinking I would lay it flat on some scrap ply drill some m8 holes for the middle couple of cylinders and use the removed M8 studs to locate it. then put the manifold over the gasket and drill through. That way it should keep it flat and stop it twisting if the drill bit bites in.

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That's pretty much exactly how I did it, only I had a bit of scrap ally instead of the ply.

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Originally Posted by clintooo

What torque would I do them up to? I think from memory the M8 are done up to 25nm. I cant think of anything else at M10 size on the car that is going into Ali for a reference point.

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$64,000 question. I want to know this as well.

What about a punch for the holes?

I'd be torquing them to the same 25nm

I'm going to be using HD belleville washers on mine and torquing to 25nm with m8 studs, top one on number 5 has a recoil so may still need to go to 10mm??

leads to the next question of what grade stud and what the head is made from

but somewhere between 25 and 30is could be about right??

FUTEK Bolt Torque Calculator | Bolt Torque Calculators


But there is nothing to punch, I just need to enlarge the existing hole for the bigger stud. :)

Quote:

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Originally Posted by clintooo

leads to the next question of what grade stud and what the head is made from

but somewhere between 25 and 30is could be about right??

FUTEK Bolt Torque Calculator | Bolt Torque Calculators


But there is nothing to punch, I just need to enlarge the existing hole for the bigger stud. :)

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One of these
10 mm wad punch - Google Search

I've made a few of these from pipe sharped and punch on the end grain of a lump of hardwood[emoji106]

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Originally Posted by Lemo

What about a punch for the holes?

I'd be torquing them to the same 25nm

I'm going to be using HD belleville washers on mine and torquing to 25nm with m8 studs, top one on number 5 has a recoil so may still need to go to 10mm??

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Last time mine was off the recoils came out of a couple of holes so I went fishing and found more. I think maybe standard coils don't like the heat.

I think the easiest and safest way is with step drill and a clamp on timber base.

Pete

I ended up going with the M10 studs for 1 & 5. Despite a whole lot of nervousness, the drilling and tapping went ok. They all torqued up to 25nm ok with no slipping.

I used the handiest tool in my tool box to enlarge the holes in the gasket.... my dremel.

when should I re torque the nuts? Ive run it for about an hour now.

probably every service ? ,,

good point. I hadnt really thought of that. I've hit them with a yellow paint marker for a visual inspection of movement of nut, but Ill add that to my service checklist.