My first step will be building a couple of exhaust manifolds. The stock 6.5L manifolds won't fit. I looked at the Humvee headers and thougth I could use them but nope, not a chance. So here I go making my own manifolds. First I had Metal Products Company ( my neighbors) laser cut some flange plates to bolt the manifold to the head.
|Laser cut steel flanges. I had Metal Products make 20 of them so I would |
have plenty to ruin while I figured out how to build the manifold.
I wanted to just make one long plate with the appropriate holes in it for the exhaust ports and bolt holes. Unfortunately, unlike other motors I've seen the exhaust side of the 6.5 head is not one machined flat surface. Instead, there is a separate machined surface around each exhaust port with raised raw casting in between. That means making separate flange plates for each port.
I found some 1-1/4" stainless steel weld up schedule 10 pipe elbows. These are just the right size to make the bends coming out of the port flanges. In the hydraulic press I mashed one end of the elbow into a rectangle shape to fit into the exhaust flange. Here it is tack welded in place.
|One passenger side exhaust elbow|
The new manifold has to be very compact. Once all the elbows were formed, fitted and welded I made a fixture to cut them all off at the same angle in preparation for welding to a 'log'.
|Four drivers side exhaust elbows|