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Thread: Manifold is not flat across the faces.

  1. #1
    Join Date
    Nov 2012
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    Acacia Ridge, QLD
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    Question Manifold is not flat across the faces.

    Hi guys I read a lot about TD-5 manifolds warping. and I have a manifold that is not flat across the faces, (Not TDi) How do they true them up? can they put them on a big belt sander etc so all the faces are on the same plane? It's too difficult a shape to put on a milling machine and use a "fly cutter" I'm thinking.
    I appreciate anyone who has advice on that tks

    simmo
    95 300Tdi Defender wagon

  2. #2
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    upper hunter
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    your on to it with the milling machine. Just the head is horizontal and not vertical.

  3. #3
    Join Date
    Jan 1970
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    Take it to an engine reconditioner, he will put it on a manifold grinder which is basically a big belt sander. It shouldn't take long, as no set up as with milling, so shouldn't be very expensive.

    Cheers, Mick.
    1968 SIIa SWB
    1978 SIII Game SWB
    2002 130 Crew Cab HCPU

  4. #4
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    Been down this road. A lot were untrue from new (is that a word?).

    I assume you've de-webbed it.

    Mine was too far gone to machine flat. Similarly, metal spraying was out, would have been too thick.

    What the machine shop was heat it up, clamp it, and it cooled flat, or at least within acceptable tolerances. No problems since.

    No idea what temp it was heated to. Way hotter than normal EGTs I suspect.

    Regards
    Max P

  5. #5
    Join Date
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    Usually done on a big linisher. Use high temperature gasket sealer when reinstalling.
    URSUSMAJOR

  6. #6
    mousie Guest
    Just got mine linished and PLR at Brendale charged me $35 dollars. They state average is 80 dollars depending on time. Mine had one stud broken and clearly was not flat and I dropped it off at 8am and picked up same day. Pretty impressed for once. Mind you removing a broken stud is another story.

  7. #7
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    Quote Originally Posted by mousie View Post
    Just got mine linished and PLR at Brendale charged me $35 dollars. They state average is 80 dollars depending on time. Mine had one stud broken and clearly was not flat and I dropped it off at 8am and picked up same day. Pretty impressed for once. Mind you removing a broken stud is another story.
    Thanks for that - I'm pretty sure mine cost just under the hundred dollar mark, once I finally found somebody who could do it. Filed for future reference!

  8. #8
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    Thumbs up manifold flat

    Moffats at acacia ridge linished the manifold for 65$, thanks for your advice.

    simmo
    95 300Tdi Defender wagon

  9. #9
    mousie Guest
    Okay so my $35 dollar job may not have been perfect as I thought. All new components used but after a trip long towing trip, to my surprise I see a tad black soot on surrounds of number 3 exhaust. All studs doing their job and all good. Yes now how to tighten and using a proper tension wrench (warren and brown). Maybe it decided to move again but only very minor in the opposite direction or just continue to settle. I did drill the stud holes on 1 2 4 and 5 by a small 0.6mm increase just in case.

    I think I will just leave it on and don't touch it.

  10. #10
    Join Date
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    Install a set of 10mm studs in the head also
    +1 on the de-web

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