Manifold Facing

~1.5mm would be easy enough to remove yourself. Get a roll of #80-#120 emery cloth and a flat piece of heavy glass or even thick MDF. glue the emery cloth down with some contact adhesive and off you go. It will take a while but you'll get it pretty flat I reckon.

JB

I'd considered throwing the belt sander at it (literally!) but I just know my luck - I'll end up with it being as wavey as the sea in 3 minutes :D Might be a last resort - if i stuff it up I can always take it to be re-done lol. I might use 400 belts though.

You'll get bored. 120's as fine as makes sense.

The message from CoyoteBoy contains these words:

How tight do you have to get the bolts to flatten it out?

Don't use a machine like that for this. You'll end up with the problem you describe. Do it as JB suggests. I've flattened carburettor flanges with a file before now.

Rob Graham

I couldnt get it to flatten out at all, the manifold bolts are meant to be at @~50lbft (alloy head) but I had them up near 80 and it still wasnt helping. Its a very fat section manifold:

I've got some fairly hefty stuff on the sander at the mo, I can finish it off with something a little finer, or maybe scrape a fine layer of exhaust paste all over it that should expand on heating lol.

The belt sander is approximately 2/3 the length of the manifold so it wont be as bad as it sounds, though I am wary as you suggest. If I'm super-careful and check regularly I reckon its do-able. If not I've only lost what no-one wanted to machine for me anyway. I wouldnt mind but only 6 months ago I binned a spare I had that was fine - sods law isnt it.

Accompanied by the sound of a chisel on slate CoyoteBoy, managed to produce the following words of wisdom

Newton Motors E and SF (Liverpool) Ltd

They've been around for 50 odd years and are used by most of the professional motor trade on Merseyside.

Pete, thanks! I'll give them a bell in the morning - nice to have a recommendation. Any rough ideas on price?

Belt sander retired to the cupboard again...

Accompanied by the sound of a chisel on slate CoyoteBoy, managed to produce the following words of wisdom

Not a clue..

That, is a largish turbo! What HP are you hoping for?!

tim.

I reckon he'd better get some cable management sorted too. The heat from the turbo alone will melt all those cables >this quickly

:) I think its a trick of the camera :D Its a CT20b (standard toyota ST205 GT-Four turbo) - good for ~350 at the fly, when i finally get the tuning right and lose the leaky manifold(!), at ~6Krpm, and something close in lb ft too. At about 17psi - though thats pushing it to the max.

:) The photo is old, yup - it does generally glow bright orange, almost semi-translucent when at decent pace. However it does have plenty of heat shielding all round, the downpipe is double-wrapped and all cabling is routed around the sides - that was taken during the fitting of my wideband AFR sensor setup.

I was only taking the piss. Honest. That is one FO turbo though. Wonder if I could shoehorn it onto my T4 2.5TDi :>)

JB

Accompanied by the sound of a chisel on slate JB, managed to produce the following words of wisdom

I suspect I'll be in for a bollocking then.

Hehe :-)

Yeah but you try changing the oil filter on it....as you can see from the picture, the easiest method involves removing the alternator!

I'm sure you could, sits quite comfortably on the side of my 2 litre, though theres not *that* much spare space afterwards lol :)