Re: 1940 Super 8 160 Model 1803 Project

Posted by Jim On 2011/5/22 22:54:43

As decided yesterday, the day was dedicated to work on the manifolds. The initial plan was to not part the intake from exhaust manifolds because the gasket-less fit that was not leaking. After inspection with the straight edge, it was evident why the exhaust gaskets didn't hold. The intake joints were about 1/32 above the exhaust. I believe the original gaskets that consisted of separate intake and exhaust gaskets may have been differing thicknesses verses the newer replacement one-piece gaskets that have common gaskets for the intake and exhaust ports. Whatever the case, the two had to part to allow for better alignment while tightening the manifold bolts.

Inevitably, bolts undisturbed for 72 years in an exhaust manifold are going to break. I was only surprised with one bolt actually came out. The other broke off, and the last had to have the head drilled out to allow disassembly. Once apart, I soaked with rust-eater and had lunch. When I returned and put Vice-Grips on the one that the head was drilled off of. It actually came out! Feeling lucky, I drilled the last one out and tried an easy out. No luck. Over to the mill, to use a 5/16 end mill allowing all but the threads to be removed basically leaving a spiraled thread. Most of it cleared out catching on the tooling, with the last coming out with a scribe. Chased the holes with a tap and all was as new.

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