Exhaust Manifold Flange Gap

[DDUSCG]

I’m the new owner of N998PC and loving it. Right now I’m working to fix a leaking exhaust manifold. 3 of the 4 connections were showing signs of leakage but the number 4 cylinder looks to be more of a flange issue. The flange doesn’t sit flush on the head. I’m planning to cut the pipe about 80% through and then bend it to sit flush on the head. Then I’ll weld the cut closed. I’d like to hear some other more experienced ideas if you have one. Thanks

[Bryan Cotton]

Sounds like a good plan. Congrats on your new airplane!

One question, have you had the pipe off yet? Besides the alignment it can fit too tight, too loose, anywhere in between. Mine are slightly tight, I have to fight to get the gasket in.

[DDUSCG]

@Bryan Cotton I have removed it. Mine is a pretty tight fit too. I could probably fly it with the bolts off. ;)

[Bryan Cotton]

I'd probably cut it, bolt it up, tack weld it, then pull it off for the final weld. You are going to need new exhaust wrap!

[DDUSCG]

I'd probably cut it, bolt it up, tack weld it, then pull it off for the final weld. You are going to need new exhaust wrap!

I don’t have power at the hanger to weld. I’m planning to bolt it up after I cut it and then use a feeler gauge to measure the gap and then remove it and reset the gap on my bench and weld it up. Thanks for the help. Can I just get the wrap at a local auto parts store?

[Bryan Cotton]

I'm sure you could. I got mine here:
https://www.amazon.com/gp/product/B002R4U72I

DO NOT buy spark plugs on Amazon though. Too much counterfeit crap out there!

[WesRagle]

Can I just get the wrap at a local auto parts store?

I'm sure you could. I got mine here:
https://www.amazon.com/gp/product/B002R4U72I

DO NOT buy spark plugs on Amazon though. Too much counterfeit crap out there!

And here is a video:
https://www.youtube.com/watch?v=Hp1uaJQZg4Q

I couldn't make friends with the SS zip ties and used hose clamps.



Wes

[Area 51%]

An old junk VW head makes a wonderful fixture.
They are everywhere.

[Bryan Cotton]

I also use hose clamps.

[jeff0196]

My exhaust wasn’t even close to fitting (more than an inch off on some flanges) and on the turbo that is all four cylinders in one piece. A local eaa chapter member that was very experienced with building many planes chuckled at my issue and said he could help. He came over with two small propane torches and we very carefully heated the affected areas to a lower red hot using one torch on each side and being very careful not to put too much heat into any one spot. When it was glowing I could bend it in place with small pliers from the flanges. Let it air cool and have never had an issue since.