LS schedule 40 exhaust manifolds - Defender Source
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  #1  
Old January 19th, 2016, 12:44 AM
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LS schedule 40 exhaust manifolds

Thought I'd start a separate thread for the construction of a pair of exhaust manifolds for my Gen III LS install. After reviewing all the available options and not wanting to end up spending $ on shipping manifolds back & forwards, will be making a set from schedule 40 weld ell's and some 1/2" flanges.

Using 1.5" primaries, and 2" collector it'll drop out to the system with 2.25" V-band couplings.

Here's a pic of a turbo manifold that's similar to what I want to end up with.... but not so shiny
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  #2  
Old January 19th, 2016, 01:26 AM
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Something a bit closer, mine will have the 2" elbow where the straight section is and the right two primaries dropping into the elbow. A 45 degree bend on the bottom of the 90 will have the V-band clamp sitting horizontal just in front of the clutch slave cylinder.

Well, that's the theory
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Old January 20th, 2016, 01:10 AM
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Ordered a set of mild steel flanges from CBR Performance, nice thing about these is there counter bored to suit the OD of 1.5" sch'd 10/40 weld els
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Old January 21st, 2016, 09:50 AM
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And some 2.25" stainless self-aligning V-band couplers plus a box of weld els. Just waiting now till they all turn up.... I hate waiting
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Old January 27th, 2016, 10:08 PM
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Got my flanges today... real nice quality

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Old January 28th, 2016, 09:16 PM
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Quote:
Originally Posted by Landy_Andy View Post
Got my flanges today... real nice quality
Silly photo bucket.... here are the flanges



And with a 1.5" elbow located in the port counter bore

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Old January 28th, 2016, 09:45 PM
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Andy:
I have made several custom exhaust manifolds out of schedule 40.
A word of experience, you cannot weld the pieces with a continuous bead and expect the manifold to fit even if you have it clamped down.
The only way to be successful is with "fish scale" welding.
In other words you tack weld the entire assembly and after a test fit, weld one small 1/8" area at a time and then wait for it to completely cool down before the next "fish scale" is welded.
This is best done on a cold winter day when you can weld multi-places, but never more than 1/8" of weld at a time.

Otherwise if you weld the whole thing up with a continuous bead, the warping will prevent the manifold from even coming close to fitting.

Good luck!
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Old January 29th, 2016, 01:19 AM
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Hi Robert,

That was my plan.... tack up, break down into sub-assemblies, then work my way around all the joints 'ticky tack' fashion with the amps cranked up a bit for good penetration, then assemble the sub-assemblies and final weld up.

Been reading up on the turbo forums and that seems to be the preferred method, even when TIG welded.

The flanges are 1/2" thick but I'll still clamp it all down to a solid plate. Just happen to have a few lengths of scrap grader blade in the back of my work truck that'll do just fine
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Old January 31st, 2016, 01:17 PM
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Made a start on the passenger side as it has to clear the starter motor and I wanted to try and use standard bends, worked out just fine with the last 2" being half a 45 degree.... and that leaves me with the other half for the drivers side.

I decided to fully weld it into place to give a solid datum to work off for the rest of the primaries, I didn't want it moving around whilst fitting them up. I think I'll add the other end next to lock it all together and then the centre two. I'm also hoping to be able to squeeze the O2 bung in just above the V bang flange. Keeps it nice and compact and I'll be able to fire it up without the rest of the system being finished





Here is the drivers side being assembled.



Once I have the drivers side in place I can work out the 'Y' pipe and order up some 2.25" bends and a 2 into 1. Think the rest of the system will be 3"
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Old February 19th, 2016, 08:11 PM
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Got the 2.25" V band flanges & clamps this week, real nice size fit to the pipe

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