Here a few pics of my MaxRev manifold. I haven't had the time to test fit it but looking at it I'm worried about how the bolt holes on the lower part of the manifold flange don't line up.

None of the bottom bolt holes line up with each other? Even the left and right ones don't match. Is this stuff normal?






THe flange is also not flat when I lay it down, the middle parts for the 2nd and 3rd runner are visibly elevated. It seems the outer part of the flange is thicker. Will I have a leaking problem? Also the wastegate flange isn't perfectly flat, will that also cause a leaking problem?

TIA

 

hmmm , that looks wierd form what i rememeber of mien, ive been seeing this alot laltey
mine leaks from the head ports, im replacingthe gasket this weekend . i hope its only that . it seems to fit on the head nicely. .. ? i dunno .

 

I had the exact same problem when my MaxRev Manifold came in (do a search, my rant thread will show up), but I just called MaxRev up, and then sent me a new manifold that day, no questions asked. I'd suggest you do the same

I really like MaxRev a lot, but this problem seems to be getting more and more common

 

That's pretty bad...as far as being un-even, as long as it's not real bad, that should not be a problem once it's bolted on. That's kind of the nature of tubular manifolds, and why they cut the flange between runners.

For the guy with the leaking problem, try a Mr. Gasket copper exhaust gasket. They're probably thicker, and copper is nice and soft. Worst comes to worst, double up on exhaust gaskets.

 

When installing you tighten inside out right????

And remove outside in???

 

well i just ordered a new one from honda, im gonna try that 1st, i figured maybe from as many times as i had my headers and shti off, prob beat it up a bit when i finally got the turbo test fitted and installed. ?

 

Yes, move from the middle out. Of course it's not that big of a deal if you have a cast manifold (hello inline pro )

Yeah, I kept re-using my stock exhaust gasket but after 4 or 5 times of taking the manifold on and off it started leaking a little.

 

maybe I'll do a test fit before calling them. All the holes on the bottom of the block do line up right? I guess this is what happens when they get tons of orders in a matter of weeks and rush production

 

the middle bolt hole is higher then the two beside it and the one outside hole is considerably higher than the other outside hole. The center three should be symentrical to allow the flange to fit either way.. the outside two make it only able to be used one direction towards the head. That looks normal to me. http://www.redpepperracing.com/gallery/albun51 Check out some of these pics it might give you an idea of how mine look

 

The bolt hole alignment is correct.

The warped flange is not. It warps because of the way it is heated and cooled during welding. It should be flat or very close to it. How far off is it?

 

How can you tell its warped? I think that's a bit odd how they put the cuts in it, probably to prevent the warping problem.

 

Back in the day we would cut the flange between ports on the headers for our V8s because very often they would not bolt down flat, especially after heating up during use then cooling down, basically what Dustin said.

Damn, just noticed this, but that thing needs some serious cleanup. The tubing looks smaller than the ports, so there's going to be some flow/turbulence problems there.


[Modified by Hatchblack, 7:44 PM 1/23/2003]

 

ok I just took some pics to illustrate possible warping. Basically there is a visible arc when looking at it straight on. At the peak it is about almost a mm off the flat surface. Seems like the effects of expansion/contraction from welding as Dustin said. I plan to use the Mr. Gasket copper gasket so hopefully this wont be an issue.

from left to right











[Modified by Pat, 11:45 AM 1/23/2003]

 

I think I can see it but I don't think it will be a problem. Take a grinder to the tubes inside those ports though!

 

Thanks for the tip Hatchblack. I didn't even make a note of that before... I wonder if its just mine that wasn't ported

 

they don't line up completely on my current manifold, nor on any of the 3 manifolds i've owned. if it fits, it fits. if you leak, get copper gasket maker and it seals right up

 

if you like the sound of exhaust leeks, leave it.

If you don't(as most would agree) take it to a good machine shop with a lathe and have them do the head flange as well as the turbo flange. I even had my downpipe flange done.

You can see already that it is warped, this is caused from welding, save yourself the headache(and knuckle scrapes) and make it <U>flat</U>.

Happyboostday

 

the inside of those runners where they meet the flange should be welded too, looks like they forgot.

not welded here


but welded here


not welded here either....strange

 

arghh

so should I match port the runners first and then get it welded inside? Otherwise the welds would be grinded away? Maybe I should just send it back.

 

looks like they didn't bolt it onto a head first before welding teh tubes to the flange

 

Send it back. It's supposed to be welded on both sides:



I wish they had done a little better job on this particular weld, looks ugly hehe

 

Yeah, I agree with Dustin, you should definetly return that one to MaxRev and get another