F-163 Exhaust Manifold Outlet Flange

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Remember Red Velvet Cake?  After being in the field making money for the owner for just over a year she came back for some maintenance work including exhaust manifold repair.  When here originally to be put back together, the pipe threads in the manifold were questionable but a 1-1/2" NPT tap seemed to clean them up sufficient to do the job.  Well at some point over the last 12 months they finally gave out and every time it rained, water would get in the manifold and when started would blow black all over the hood.  Attempts to braze the pipe to the manifold in the field proved fruitless and several attempts by myself in the shop with various different rods and processes didn't turn out any better so it was off to the machine shop for a "flat top" cut.  Once the manifold was back I used an outlet flange off a Clark fork truck unit to locate the new 3/8-16 bolt holes.Then I cut a flange out of some 3/8" flat stock with the Pak-Master 100XL and cleaned up to finished shape with the grinder and bored out on the lathe which was real fun with its 3-jaw chuck that required shimming to center up.  Then came truing up one end of the 1-1/2" coupler on the lathe so it fit squarely in the new flange.More on the flange in post #2 . . .MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:. . . showing how the pieces fit together . . .. . . and my amateur TIG welds on the outside and inside.Syncrowave 180 SD set to max and using the peddle.3/32" 2% thoriated sharpened to a dull point15cfh argon1/16" ER70S2 fillerInstallation complete with a fresh piece of galvanized 1-1/2" pipe.Thanks for looking.Last edited by duaneb55; 06-30-2013 at 09:50 PM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:That will hold no problem..But there is too much overcut..Too much underweld..Not nearly enough burn thru and contamination...The colors are completely incorrect..No filler rod still attached anywhere???????You know the story...You get all the fun jobs......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I dipped the tungsten once.  Will that do?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55I dipped the tungsten once.  Will that do?
Reply:Shewwwww!  Dodged that bullet. Having been in the field for over a year she's not quite as pretty anymore but a worker just the same.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Nicely done - thumbs up I have not been around long enough to see the flat top cut on the manifold before - pretty cool Dave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by smawgmaw  Dipped into what?
Reply:Good looking fix Duane. I've thought many times about a solution to this problem on these machines, never entered my mind to bolt it with a flange like that. My question though is why wouldn't you just weld a  pipe into the flange long enough for the flap & do away with the threads entirely?Only when the last tree has died and the last river has been poisoned and the last fish has been caught will we realize we cannot eat money.                                         -Cree Indian ProverbSA 200 LincolnVictor Torches
Reply:Originally Posted by duaneb55Hot sauce.  Yeah, that's it - hot sauce.
Reply:Thanks Gizzard and I definitely considered the pipe only but I figured this way still provides a female NPT thread as original and leaves the door open for a number of options - including a pipe only with a flange welded to it. MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Thanks Mike and I'll be listening.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Duane I have done the exact same to my 200 except that's its carbon fitting to a stainless steel exhaust custom engraved all pretty like. I want to get a new manifold due to the years of use they kind of deteriorate. Love what you did with it
Reply:Nicely done Duane!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by zapsterThat will hold no problem..But there is too much overcut..Too much underweld..Not nearly enough burn thru and contamination...The colors are completely incorrect..No filler rod still attached anywhere???????You know the story...You get all the fun jobs......zap!
Reply:Nice fix DuaneGeezerPower Mig 255C185 TIGBlue 175 MIGRanger 8 Kohler 20HP1974 5K Lincoln/Wisconsin Powered (Cherry)Victor/Harris O/AK 487 Spool Gun
Reply:now you just needa chrome plated flutter valve to top it all off. lolThere are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by rschreckI really want to hear this story.