flatten turbo manifold flange?

[chimmike]

So I've got a turbo manifod with a flange that is slightly warped on the outside portions (outside the runners) for the most part. i.e. not all the way around the runners, just the opposite side lengthwise of the flange. also, the flange is 1/2" mild steel, runners are SS.

maybe 1/16" max deflection on one side, less on the other. If I am able to clamp the center down and heat this thing up with a torch, clamp the outside down after heating, what's the likelihood it'll stay flat?

Also, will a mapp torch from say, ace hardware be enough? Or am I going to have to fill my O/A setup?

[Gamble]

What type of metal is it? And warped after you welded?

[chimmike]

I got it for a smokin' deal because of the flange, guy didn't want to deal with it.

mild steel 1/2" flange, stainless runners.

[zapster]

Bridgeport and a fly tool..

...zap!

[Gamble]

Yep, I would say have it machined at the local machine shop.

[chimmike]

yeah, I've tried 5 machine shops now, same answer everywhere: "I don't have any way to hold it for machining"

been 'round that block.

[zapster]

Originally Posted by chimmike

yeah, I've tried 5 machine shops now, same answer everywhere: "I don't have any way to hold it for machining"

been 'round that block.

I could do it..
We do ANYTHING.

Probably have a fixture to put it in the Blanchard...

...zap!

[chimmike]

Originally Posted by zapster

I could do it..
We do ANYTHING.

Probably have a fixture to put it in the Blanchard...

...zap!

yep, but you're not in the Tampa Bay area, and shipping this beast costs about $40 each way, haha!

I'm trying to get my hands on a belt sander big enough, and spent 45 mins at a shop belt sanding it today and it's still got a ways to go.

[Aceman]

Originally Posted by chimmike

yep, but you're not in the Tampa Bay area, and shipping this beast costs about $40 each way, haha!

I'm trying to get my hands on a belt sander big enough, and spent 45 mins at a shop belt sanding it today and it's still got a ways to go.

If you spend $80 bucks on shipping so what?

Do you want it fixed or do you want to keep screwing around with it?

[vettepicking]

ill do it, im on the east coast of FL. if you can come here ill fly cut on the b-port. free

[jakeru]

You can flatten that yourself. First, do the torch trick that you proposed. Or, just start with a big, aggressive cut flat file. Keep pressure on the center of the flange (the file should never lift up off an edge) so you don't bite into an edge of the flange, and rotate the file 45-90 degrees or so periodically as well. I would clamp the manifold in a vice, and stroke it with the big flat file moving. That way you can put some real "gusto" into it.

Since the file probably won't cover the whole flange, keep it moving so it doesn't bite in. All this is kind of hard to explain, but if you've done it once, it will be easy.

Then (or alternatively to the above), you can finish it off with a hand-held sized chunk of metal with one flat side with a piece of sand paper wrapped around it. 80 grit should work well. Go for the "open coat" because it won't fall apart so quickly. Keep going until the surfaces are all uniformly shiny, and when you're done that piece of steel will be flat and is going to seal well.

This will take some "elbow grease" no doubt, but you'll be able to get it done yourself, and with great results, and no machine shop needed.

[jdchmiel]

big belt sander is 'flat enough' for an exhaust gasket to keep it sealed.

[dave powelson]

Automotive machine shops routinely surface manifolds.

[chimmike]

this is a turbo manifold though, so it's funky shaped. the auto machine shops I went to looked at it and said "I got nothin to hold this in place" and turned me away. Helpful, eh?

[Gamble]

Got a pic of it, maybe that will help give people some ideas.

[WookieWelding]

+1 to what zap said

[AndyA]

Buy a small cheap surface plate ($20 or 30), some spray adhesive, and sandpaper sheets. Then use jakeru's method, but use the surface plate that you know it's flat rather than some unknown piece of "flat" metal. You can also use the surface plate to test how well you corrected it with the torch. Maybe you'll need to reapply the torch to avoid having to sand off too much material.

The milling machine would be nice, but I don't have one.

[chimmike]

So, I'm thinking clamp down on either edge of the flat portions, then heat those portions up, and use a c-clamp to clamp down the warped portions of the flange, let it cool slowly, and that should work, right? For the most part?

Following up with a file and sanding as described?

[AndyA]

clamping it flat may not be enough. It may spring back when you unclamp it. If it does, try clamping it with some shims under it where needed so it springs back straight.

[chimmike]

I'm actually going to try bolting it down to my 1/2" plate drill press table, flat, then heat it to relieve stress, and let it cool. We'll see how that works?

[zapster]

Like Andy stated..You can't bolt it down flat and expect anything except the same result as when you started after unclamping...by at least making it bend in the opposite direction where it is screwed up before heating will yield better results..
And I am betting there is not much on this that is actually straight.

You also stated you spent so much time with a belt sander so that means you pretty much got nowhere doing that..

Stop screwing around and get it done by someone somewhere with the correct equipment and get it over with.

There are some things that need the right stuff to get accomplished or else they will never get done correctly.

...zap!

[chimmike]

yeah....well this is the funny thing. The portions where the runners themselves are is mostly flat. It's the outside portions that are warped.

I'll see what happens, and maybe ship it over to vettepicking and take him up on his offer.

[MikeGyver]

Many machine shops use a big belt sander to resurface heads, etc. Just find a shop with a "belt sander".

[chimmike]

Originally Posted by MikeGyver

Many machine shops use a big belt sander to resurface heads, etc. Just find a shop with a "belt sander".

been up and down that road too. that's why I finally went back to a fab shop I found locally, and the owner was nice enough to let me use his big belt sander and just sit there for about 45 mins. My lunch break ran out though and I had to get back to work, haha.

[astaindsoul5446]

+1 to belt sander