its for a 97 gti vr6. how should i do it? any1 no of any templates for this type of car. what shouls i use to make it ect.? welding it is not a problem. also i was wondering if i could use a 1/4" sheet off aluminum for the flanges ect. thanks in advanced

 

Hmmm...not sure if I would use aluminum, but I have never made a manifold.

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don't use aluminium for the flange.
uhmmm it's a custom mani soo you have to custom fab it your self...measure and test

 

Why aluminum sucks for exhaust purposes:

Image courtesy of HMT.

 

Just use your stock mani and chop off the pipes. Voila! You now have a flange!

 

guaranteed to crack out!

that's a good plan.

 

whats gonna crack out

 

Use your exhaust gasket and trace the pattern on a 3/8" thick piece of flat steel (I've used 4" X 4" X 3/8" angle) cut it out square. Use a 3/8" drill bit and drill around the outside of your trace..........yes it's a million holes. Then I used a jig saw with 24 teeth/inch to cut the material between the holes. Use a grinder to smooth out the material. (It will look like someone bit into it all the way around)

Use hole saws to cut the individual holes for the exhaust. If its oval use a hole saw to cut as close as possible then use a die grinder to remove the rest of the material.

For the bolt holes just drill out where you traced it out from the gasket. (preferrably on a drill press for accuracy)


If anyone needs clarification IM me or I will take a few pics and post them up of the steps.

I've mave all my flanges using this method.

 

I've found out that the $25.00 flange is worth the money. The time it takes to make flanges is much greater than the $25.00 they cost.

 

True dat!! But he wants one for a VR6, so if they make one for his appliction and its $25, go for it.