Just did something really stupid
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Joined: May 2000
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Just did something really stupid
82' f-150 300-6
Today I was replacing the pipe from the manifold to Cat because it had a couple really bad holes. It was really hard to get off, from freeing up the frozen nuts, to removing the stuck end where it enters the the pipe for the catalytic converter. Several hours of cursing and bruised knuckles finally got the pipe removed but also set the stage for disaster.
The new pipe that Canadian tire ordered in for me and they claimed would work, matched up perfectly with the bends of the old pipe and had what appeared to be the right sized flange on the end. They also gave me the "donut" that is supposed to seal the pipe to the manifold.
When I went to install the new pipe, I noticed that the donut had the same profile as the joining end of the manifold. I concluded that that must just be the old donut still stuck inside the manifold. I then proceeded to smack and pry at the end of the manifold with hammers and screwdrivers hoping to free up what I thought was the old donut. After it still didn't budge, I made the big mistake of cutting some slots and even drilling a hole in it!
Just to simplyfy for anyone who is confused: I mistook the piece at the end of the manifold where it joins with the pipe for a donut, and I hacked it up a bit.
After It still didn't move I sat down at the computer here to try and figure it out. After reading a couple posts it appears to me that 300-6's from 1980 on, didn't even use donuts. Did I just wreck my manifold? Is there any way to fix it? I was thinking maybe I could just weld a bead into that hole and around those slots and then just grind it down to shape after. Would that work? What kind of rods would I use?
I checked, and the flange on the end of the old pipe does not extend up far enough to cover the hole (although it does cover the slots mostly). BTW the new pipe does not fit onto the end of the manifold, the flange on it is the same as the old pipe, except the new pipe has about a 1-1/2" length of smaller diameter pipe that extends out past the flange / flare end on the pipe and will not fit into the manifold. I figured that if I can fix the flange on the manifold, I could make this pipe fit by just cutting the 1-1/2" off flush with the inside of the flange / flare.
If anyone can make sense of this post, please help!
Today I was replacing the pipe from the manifold to Cat because it had a couple really bad holes. It was really hard to get off, from freeing up the frozen nuts, to removing the stuck end where it enters the the pipe for the catalytic converter. Several hours of cursing and bruised knuckles finally got the pipe removed but also set the stage for disaster.
The new pipe that Canadian tire ordered in for me and they claimed would work, matched up perfectly with the bends of the old pipe and had what appeared to be the right sized flange on the end. They also gave me the "donut" that is supposed to seal the pipe to the manifold.
When I went to install the new pipe, I noticed that the donut had the same profile as the joining end of the manifold. I concluded that that must just be the old donut still stuck inside the manifold. I then proceeded to smack and pry at the end of the manifold with hammers and screwdrivers hoping to free up what I thought was the old donut. After it still didn't budge, I made the big mistake of cutting some slots and even drilling a hole in it!
Just to simplyfy for anyone who is confused: I mistook the piece at the end of the manifold where it joins with the pipe for a donut, and I hacked it up a bit.
After It still didn't move I sat down at the computer here to try and figure it out. After reading a couple posts it appears to me that 300-6's from 1980 on, didn't even use donuts. Did I just wreck my manifold? Is there any way to fix it? I was thinking maybe I could just weld a bead into that hole and around those slots and then just grind it down to shape after. Would that work? What kind of rods would I use?
I checked, and the flange on the end of the old pipe does not extend up far enough to cover the hole (although it does cover the slots mostly). BTW the new pipe does not fit onto the end of the manifold, the flange on it is the same as the old pipe, except the new pipe has about a 1-1/2" length of smaller diameter pipe that extends out past the flange / flare end on the pipe and will not fit into the manifold. I figured that if I can fix the flange on the manifold, I could make this pipe fit by just cutting the 1-1/2" off flush with the inside of the flange / flare.
If anyone can make sense of this post, please help!
Tuned
Joined: Jul 2001
Posts: 430
Likes: 0
From: Deatsville, AL
Just did something really stupid
Glad I'm not the only one that screws up. I've used nickle rod to weld cast iron with good success. Tell your local welding shop what you're trying to weld and they usually know what rod to use.
Since exhaust leaks are really anonying and dangerous under the cab I'd take the manifold off, build it up with weld and then grind it down and fit the header pipe on the bench. Lots of work but the other choice is a new (used) manifold.
Bob
'66 7 Litre, top loader, 3.25 Traction-lock, Sidewinder Intake, SCJ Exhaust
'88 F150 LWB 4x2, XLT Lariat, 302, 5 speed, 3.08
'99 Ranger, 4x2, 3.0, 5 speed, 3.73 posi
Since exhaust leaks are really anonying and dangerous under the cab I'd take the manifold off, build it up with weld and then grind it down and fit the header pipe on the bench. Lots of work but the other choice is a new (used) manifold.
Bob
'66 7 Litre, top loader, 3.25 Traction-lock, Sidewinder Intake, SCJ Exhaust
'88 F150 LWB 4x2, XLT Lariat, 302, 5 speed, 3.08
'99 Ranger, 4x2, 3.0, 5 speed, 3.73 posi
Junior User
Joined: Jun 2001
Posts: 72
Likes: 0
Just did something really stupid
My dad's 1981 Ford F-150 with a 300 I6 has the donut.
[font color=blue]1977 Ford F-150 Explorer 2x4 (460)
[ul][li]Flowmaster 40-Series with 2.5 inch aluminized duals
[li]14in Edelbrock chrome air cleaner with a K&N filter
[li]P275 60R 15 tires
[li]Jensen CD player with 6 speakers (subs & an amp on the way)[/ul]
[link:communities.msn.com/400EXWorld|My ATV Website]
[font color=green]Talk to me on AOL messenger -- [font color =red]EXRiders400EX
[font color=blue]1977 Ford F-150 Explorer 2x4 (460)
[ul][li]Flowmaster 40-Series with 2.5 inch aluminized duals
[li]14in Edelbrock chrome air cleaner with a K&N filter
[li]P275 60R 15 tires
[li]Jensen CD player with 6 speakers (subs & an amp on the way)[/ul]
[link:communities.msn.com/400EXWorld|My ATV Website]
[font color=green]Talk to me on AOL messenger -- [font color =red]EXRiders400EX
