Posted by Jackson Reimund on Thursday, January 25, 2001 at 12:49PM :
In Reply to: 251 Exhaust Manifold Repair ??? posted by Johnny Burrito on Wednesday, January 24, 2001 at 10:19PM :
Hello Johnny,
Make a sandwich plate over the top of the broken flange. Leave the broken one just as it is.
Take a pattern off the flange of the exhaust outlet. Then make a new one out of 3/16” or 1/4” plate. Make it slightly wider than the flange. Drill your four bolt holes and make sure they fit. Now measure the diameter of the manifold just above the broken flange and torch cut this hole diameter into the flange. Don’t oversize here. Now cut this new flange in half across the two thin sides. Now fit the two halves together over the top of the broken flange. Now with a die grinder or such grind the inner hole to fit the two halves together and with the bolt holes matching. You may have to do some light cleanup on the manifold with the grinder. Make sure it will rotate around. Now weld the two halves together. Gas, wire or stick. First one side then rotate the plate and weld the other side. When your done the plate will be just loose enough to rotate about to fit the longer bolts and sandwich the broken flange between the new upper flange and the exhaust flange. Use brass nuts. You can do this without taking the manifold off the truck.
I did this on my truck (237 same manifold) about twenty years ago and have had it apart and back together several times and still working fine.
Best of luck, ... Jackson
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