How I fixed the exhaust leaks on manifold & flange surface

[dom14]

This is what I did to fix the broken stud and leaking surface of the exhaust manifold and Y pipe flange.

I also used high temperature copper sealant on manifold gasket even though it wasn't necessary as I sanded a surface
perfectly flat.

These pictures are self explanatory.

[dom14]

More photos

[dom14]

This is where I used sanding boards and a make shift sanding table to flat sand the flange surface and manifold surface.

BTW, make sure to wear a hankie over the nose or a mask. The iron dust starts flyng and you can end up breathing lot of it while sanding. I had black boogers coming out of my nose next day, I had to keep blowing my nose over and over in the shower. Also, it can make you feel bit sick.

[dom14]

Second lot of sanding pictures.

[dom14]

Third lot of sanding pictures.

[dom14]

Use new gaskets, or use a ceramic water based sealant between the two layers of the perforated metal gaskets, as well as both outer sides.

For exhaust manifold I used the old gasket as it was still in good condition due to my use of exhaust sealant on it last time.

High temperature copper sealant works fine with the exhaust manifold end gasket, but not on the exhaust flange(the temperature is way too high there).

For the flange, water based ceramic sealant like Maniseal is the only solution(if not a brand new gasket).

[LostBenji]

New manifold with turbo would have been on the cards if mine.

[dom14]

New manifold with turbo would have been on the cards if mine.

I wouldn't wanna go turbo without EFI conversion & bottom end rebuild or a low km bottom end(if I can find a one).

[LostBenji]

on the RB30?

[dom14]

on the RB30?

We're talking about RB30 Patrol, aren't we?!