How do you guys cut your flanges??
Guest
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How do you guys cut your flanges??
Hey guys, i'm wondering how you guys cut your exaust manifold flanges for your custom/log style manifolds? I know there are people on this board that sell them, but i'm not looking to buy, i want to make one myself.
Now i know one could use a plasma cutter and chop out 3/8 to 1/2 flanges in no time. But simply said, i don't have upwards of 2-5 grand for one, and don't know anybody that has access to one. Therefore here are my options for a cheap method to cut flanges ( 3/8 to 1/2 inch), and they don't have to be pretty, they just have to get the job done:
1. Metal bandsaw from harbor freight (cheap 200 dollar one), or some sort of cheap JET bandsaw.
2. Chop off saw or angle grinder with cutting disk ( dangerous as hell if that disk fractured and turned into shrapnal.
3. Oxy/aceletane flame cut
4. Jig saw, sawzall, hacksaw, blah blah blah
And for cutting the holes i would probally buy a small drill press with a bi/metal hole saw set at the lowest speed.
So give me your opinion on the best and cheapest way to get it done.
Now i know one could use a plasma cutter and chop out 3/8 to 1/2 flanges in no time. But simply said, i don't have upwards of 2-5 grand for one, and don't know anybody that has access to one. Therefore here are my options for a cheap method to cut flanges ( 3/8 to 1/2 inch), and they don't have to be pretty, they just have to get the job done:
1. Metal bandsaw from harbor freight (cheap 200 dollar one), or some sort of cheap JET bandsaw.
2. Chop off saw or angle grinder with cutting disk ( dangerous as hell if that disk fractured and turned into shrapnal.
3. Oxy/aceletane flame cut
4. Jig saw, sawzall, hacksaw, blah blah blah
And for cutting the holes i would probally buy a small drill press with a bi/metal hole saw set at the lowest speed.
So give me your opinion on the best and cheapest way to get it done.
Guest
Posts: n/a
Re:How do you guys cut your flanges??
Yeah i would for my car at least, since like most other people here have a honda. But what if i want to build a turbo manifold for my buddies 1976 toyota corrola?? I doubt roadrace or any other companies would carry flanges for that corrola's engine, lol.
Like i said earlyer i want to make one myself! I love having the satisfaction of building something entirly from scratch. Being able to turn hunk of plate steel a few fittings into a peice of art is just ------- great.
Like i said earlyer i want to make one myself! I love having the satisfaction of building something entirly from scratch. Being able to turn hunk of plate steel a few fittings into a peice of art is just ------- great.
1.0 BAR
Joined: May 2003
Posts: 443
Re:How do you guys cut your flanges??
building an exhaust manifold from scratch is a bitch. i'm on my second one, but i use a mill. the cheapest way for u would be a band saw, then use a whole saw on a drill press and widen the wholes accordingly w/ a die-grinder. good luck oh yeah be sure to bold the flange down perfectly flat when welding the pipes on or it will flex and won't seal.
0.5 BAR
Joined: Jan 2003
Posts: 178
Re:How do you guys cut your flanges??
This is what I did:
1-On a 3/8" thick plate I traced the exhaust gasket with either spray paint or a scribe.
2-Take the material to a drill press.
3-Using a 3/8" drill bit, drill holes along the outline of the trace. Not exactly on the line but enough so that the finished hole is 1/16 - 1/8 from the line.
4-Use a jig saw with a metal blade to cut between the holes
5-Use a 4/12" grinder to smooth out the "jagged" edge to the outline of the gasket
6-Do steps 2-4 for the inside holes
7-Use a die grinder with a carbide burr to smooth out the inside holes and some tapered abrasive rolls to finish it off.
You can get the tapered rolls from a porting kit. If you need more info. IM me.
1-On a 3/8" thick plate I traced the exhaust gasket with either spray paint or a scribe.
2-Take the material to a drill press.
3-Using a 3/8" drill bit, drill holes along the outline of the trace. Not exactly on the line but enough so that the finished hole is 1/16 - 1/8 from the line.
4-Use a jig saw with a metal blade to cut between the holes
5-Use a 4/12" grinder to smooth out the "jagged" edge to the outline of the gasket
6-Do steps 2-4 for the inside holes
7-Use a die grinder with a carbide burr to smooth out the inside holes and some tapered abrasive rolls to finish it off.
You can get the tapered rolls from a porting kit. If you need more info. IM me.
Guest
Posts: n/a
Re:How do you guys cut your flanges??
Originally Posted by spiceisler
This is what I did:
1-On a 3/8" thick plate I traced the exhaust gasket with either spray paint or a scribe.
2-Take the material to a drill press.
3-Using a 3/8" drill bit, drill holes along the outline of the trace. Not exactly on the line but enough so that the finished hole is 1/16 - 1/8 from the line.
4-Use a jig saw with a metal blade to cut between the holes
5-Use a 4/12" grinder to smooth out the "jagged" edge to the outline of the gasket
6-Do steps 2-4 for the inside holes
7-Use a die grinder with a carbide burr to smooth out the inside holes and some tapered abrasive rolls to finish it off.
You can get the tapered rolls from a porting kit. If you need more info. IM me.
1-On a 3/8" thick plate I traced the exhaust gasket with either spray paint or a scribe.
2-Take the material to a drill press.
3-Using a 3/8" drill bit, drill holes along the outline of the trace. Not exactly on the line but enough so that the finished hole is 1/16 - 1/8 from the line.
4-Use a jig saw with a metal blade to cut between the holes
5-Use a 4/12" grinder to smooth out the "jagged" edge to the outline of the gasket
6-Do steps 2-4 for the inside holes
7-Use a die grinder with a carbide burr to smooth out the inside holes and some tapered abrasive rolls to finish it off.
You can get the tapered rolls from a porting kit. If you need more info. IM me.
I will pm you if you you don't want to reply to this thread anymore, but i bet it would be helpfull to talk in this thread, as i bet there are others who want to make their own manifolds, but can't afford the expensive equipment.
0.5 BAR
Joined: Jul 2003
Posts: 113
Re:How do you guys cut your flanges??
I bought 2 different 5 bolt flanges that neither fit so after the money and frusteration I went down the street to a machine shop and bought a 4x6 piece of steel. He charged me 3 dollars....i took a sawzaw and cut the basic square shape.......didnt need to cut it exact just as long as it sat flush on the exhaust side, drilled the holes and had pipe welded to it. So after 3 dollars and a couple hours of work...it was easier then spending the 25 dollars....the 2 times i did...
0.5 BAR
Joined: Jan 2003
Posts: 178
Re:How do you guys cut your flanges??
Hirostyle:
You can do it with a hand drill but it will, of course, take longer. Not only that, your hand will get tired and sore. You can try that and it can be done in a day.
Here is an interesting article.
You can do it with a hand drill but it will, of course, take longer. Not only that, your hand will get tired and sore. You can try that and it can be done in a day.
Here is an interesting article.
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