Can you use some of that good timber you have around and put on end of the plate on it then drive onto it with a vehicle to bend it the other way?
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I'm chasing a chirp/whistle under load that goes away after a few minutes so I replaced all the vacuum lines everywhere , then I pressure tested the intercooler - leaking like a sieve so ordered a new tigged 1 , bypassed it & plumbed the intercooler pipes together but the noise is still there , leaking intercooler a usual hiss not chirp so I didn't expect it to be that anyway , I then pulled the inlet pipe off the turbo & found the turbo to be fine , then I pulled the heat shield off the manifold to have a look for soot leaking around it anywhere to no avail so I pulled the EGR pipe off & (allegedly) made up a block off plate out of stainless using the original stainless gasket as a template for the manifold end - I'd already (ALLEDGEDLY) blocked it off at the other end but I'm told that pipe around the back can split or develop holes so this'll eliminate that . So to summarise what I did to my Patrol today - I pulled a heap of parts off it 😝
Yea that rust out against the fire wall and the pressure makes em blow..
But maybe check your exhaust manifold.
They are known to warp and leak. It may be early if yours is only doing it when cold and the sealing once hot..
Don't tension the manifold bolts though.. they may easily snap..
Get new ones and a new gasket.
If it is warped it'll need a skim flat again.
Yeah I've read they're prone to warping & leaking but I was doing all the smaller jobs 1st hoping to find something before having to pull the manifold off - can't see bugger all with the heatshield & everything on it . Having said that I can't see any leaking soot around it at all anywhere . It's a 3.0lt & doesn't blow any coal ( like a proper diesel should ) but I would have thought I'd see some sort of sign if it was leaking ? I rekn now that I've got so much off it I'll just take the manifold off & check the face of it & put in a new gasket .
Replaced the 7 pin round socket with a Narva metal one, because the pup ate the plastic ones lid. I am impressed with quality of the Narva as it has all brass connectors.