I6 / 300 (66 F-250) - Exhaust
 

My truck was missing a gasket at the manifold > pipe connection. Here's what it looked like (makes for a loud, smelly cab):

https://cimg4.ibsrv.net/gimg/www.for...28831c5dba.jpg

Thinking maybe it would be a quick/easy (cheap/convenient) fix for a muffler place, I took it over to a local place that had been recommended. He was booked a few days out so told me I'd have to make an appointment and that it would probably be ~$100. He told me to soak the nuts/studs in wd40 every night for a couple days in hopes of the nuts being able to be worked loose and not have to be cut off. Thinking that if that's all it took to get them workable I might as well attempt myself, I did. I soaked them thoroughly and let sit for a bit. And then got them both to turn. Not too bad at all. Here it is now:

https://cimg6.ibsrv.net/gimg/www.for...27b8d43e51.jpg

What do I need to get? It seems like it would be standard enough that I could get it at a local place (oreilly's etc), but not quite sure what to look for/sizing since there isn't really anything to take off further (hopefully). Would it be smart to replace the nuts with stainless?

As well, the exhaust isn't exactly well-hung so I'm curious what I need/what I can do to hang it better and/or properly. Short-term to get back together would be initial goal, longer term I'm all for upgrading/updating/replacing. Here's what it looks like right now by the muffler:

https://cimg5.ibsrv.net/gimg/www.for...8691339f15.jpg

So I was able to find a gasket from O'reilly's tonight which fit and seems to work great. For anyone else's reference, the exhaust pipe is 2"; the part I used is Nickson Exhaust Pipe Gasket 31400.

I snugged it up with a couple new nuts and lock washers. It's so quiet now that it doesn't seem like the same truck at all. Now that it's quieter and doesn't have the wide open exhaust, I see another place that exhaust is leaking, possibly not quite as easy of a fix? Circled in red below, looks like maybe a small crack in the cast iron. Is that part of my exhaust manifold? How big of a deal is that small leak?

https://cimg2.ibsrv.net/gimg/www.for...c4811508f.jpeg

Also still would love any thoughts on better/proper way to hang the exhaust.

C6AZ-9450-D .. Gasket-Inlet Pipe to Exhaust Manifold - 2.50" O.D. x 2.03" I.D. x .58" thick / Obsolete

1965/69 F100/600 240/300 // 1969/74 E100/300 240/300 // 1969/79 F100 302 // 1975/79 F150 302.

There is a gasket there and to replace it you need to pull the manifolds, they are bolted together. It is bolted together to use exh gases to heat the intake.
Once off the motor unbolt the 2 manifolds, bolts may break use heat to help get them out. If they break you will need to deal with them. Drill and easy out or machine shop.
Clean everything and bolt the 2 manifolds together and back on the motor using new gaskets.

Now being you have the 2 manifold apart and the bolts broke off in the exh manifold might be the time to go with EFI exh manifolds.
Link to my EFI manifold swap.
https://www.ford-trucks.com/forums/1...questions.html
Besides getting the manifolds, new (Dorman help) at auto parts store, or used at junk yard. You will need to get the Y pipe.
The other thing is a heater plate that bolts to the bottom of the intake to heat it with hot water
Ford 240/300 Products

After the manifolds are on the motor, install the Y pipe and you need to figure how to mate the Y pipe to your exh system. I don't think that would be too hard.
The wire you have as hangers I would replace with .... get this ... hangers. The parts store has them might try ones made for your truck as a starting place.
Dave ----