Thought I'd share my newest brain fart with all of you lest it may help
someone in the future.
We've all been there. Yank an exhaust manifold for some reason or another
and damned if it'll go back on, the holes on one far-side of the manifold
never line up; you can always get 4 bolts in without a problem, but the last
two are always off by 1/8" or so. I used to just heat up the manifold with
a torch, then burn the piss out of my hands while working with a 400*
manifold trying to get it back on.
Had to replace both donut gaskets today on my 88' C1500 and had to pull both
manifolds to get the old flange studs out. Neither manifold would line back
up when I went to put it back on. Didn't feel like screwing around with my
torch. So, using a die grinder I "notched" an exhaust manifold bolt about
1/8" on the un-threaded part of the shaft. I then put the manifold in
place, screwed this bolt in 4 turns into the frontmost hole with the notched
side of the bolt facing the front of the truck. This gave me enough play to
get the rest of the bolts in, working from back to front, replacing the
notched bolt last with a new bolt. Did it on the other side as well and it
worked like a charm. Saved time, pain, and it now has a place of honor in
my toolbox for the next time I need it.
Maybe I should make a whole bunch and sell em' on E-Bay for $2.00? ;-)