I need....an exhaust manifold!!!

[rlearp]

That would be "an" exhaust manifold, not "and". ;-(

Well, I had a ball at my track day this weekend and the Lotus did great, ran strong. Jeff Young had his there too and I'll post some pics on another thread.

However, when I got my car I knew it had a hairline manifold crack that was going to cause problems in the future. Over the last two weeks there has been a little ticking noise, nothing big. But, after a few sessions on the track at 4-7k RPM and with a cherry red maifold and turbocharger it has had it. The little tick that could is now a major clacking, like a B&S lawnmower! And, it is now leaking since the car wants to spit and pop a lot, like you normally get with exhaust leaks.

So, anyone got a used Lotus exhaust manifold available? Could I be so lucky? If you do let me know how much you want for it. I'd rather get a sound one that have the one I have pinned and welded, but pinning and welding, when done correctly, can do the job. Plus, I haven't even gotten it off yet so I don't know if is in a spot that is candidate for that.

Thanks folks,
Ron

>>> Edited by rlearp on Sunday 4th July 14:34

[JeffYoung]

Come on guys, help Ron out...lol....he broke the manifold on the track, doesn't that earn him a Purple Heart from Lotus or something? Seriously, his car was FUN to watch on track. It's got a better turbo and a chip he modded himself, plus a SWEET exhaust. It's fast, much faster than my SE, and it shoots flames. Cool way to keep the BMWs off the bumper.....

Since this is one that we will all face at some point, has anyone had any luck in welding and pinning the manifold, or is replacement the only way to go? We are trying to figure out the most economical way to get Ron's Green Meanie back to shooting healthy flames again.

[dr.hess]

One of these days, likely after I finish building my Seven, I would like to build one of these manifolds out of 304 stainless tubing. If anyone (US) has a used but cracked, etc., one they are willing to part with for shipping expenses, lemme know. I need something to make a jig from.

Dr.Hess

[jk1]

Ron,

I feel your pain.

I pulled my engine this weekend to do some major maintenance and mods and found a crack about 3" long on the underside of mine. Wasn't even making any noise.

Oh well, just add it to the list.

Jim

[rlearp]

Thanks for the help Jeff, but I don't think anyone has anything that would cover it. A header is a good idea, but I'd make my own with bracing, they're too expensive to purchase. Headers are easy to make as long as you have a jig.

Looks like it'll have to be removed and repaired,

Ron

[joey Licata]

Ron,
Sorry to hear about your problem. I had the exact thing happen to my 1991 SE a few months ago and had a S/S header made for the car. It looks great and definately improved top end power. A friend of mine that does a lot with Honda turbo cars made the header for me for around 1500.00, which is about the same as what you'll pay for a manifold from Lotus. You can have it welded, if you remove it from the car and use nickle rod and pre-heat the manifold just before welding. The nice thing about replacing it is, IT WON'T CRACK AGAIN! I'm also having him make a new S/S downpipe now, so my complete exhaust system will now be S/S. If interested, I can try to take some photos of it, so you can check it out. Definately money well spent on a nice upgrade!

Good luck!
Joey

[jk1]

Would love to see the photos, send 'em on.

[Dr.Hess]

Post 'em. Here is one I made:



All 304 stainless.

Dr.Hess

[johnwatkins]

Several people have investigated making a SS tubular manifold and decided it's not worth the effort.

Here's an extract from LEW

www.lotusespritworld.com/EMaintenance/manifold.html (scroll to the bottom)

Cheers,

John W

[joey Licata]

The car is currently in the shop getting a new radiator made, but I'll try to get by there soon to take a few pics. As for the thread on LEW, they are totally correct about the weight of the turbo possibly causing problems, due to the extreme temperatures. My manifold (header) was designed with this in mind and has a upper braket, to help support it. I'll get some pics posted as soon as I can.

I guess I should have waited to reply to Ron's thread until I had some good pics to share - sorry

Joey

[benfell100]

I think the race prepped Esprit in Germany has a stainless one as well. Don't know how he got round it, maybe he just used thicker metal?...
Dom