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  #46  
Old 04-02-2020, 12:52 PM
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Originally Posted by OM616 View Post
I cut the 5th exhaust port off of a 617a exhaust manifold, I then cut off the end bolt boss from the 616 manifold and welded it to the cut down end of the 617a manifold.

Now that you mention it, I do recall someone selling an adapter plate, but do not recall who it was. Personally I would not like how it would look, but it would do the job lol.
Ah-ha, thank you for that.

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  #47  
Old 04-02-2020, 03:19 PM
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Originally Posted by OM616 View Post
I cut the 5th exhaust port off of a 617a exhaust manifold, I then cut off the end bolt boss from the 616 manifold and welded it to the cut down end of the 617a manifold.

Now that you mention it, I do recall someone selling an adapter plate, but do not recall who it was. Personally I would not like how it would look, but it would do the job lol.
Any issues with the welding holding up?

I was able to get a forum member to braze the exhaust manifold for me, but it was definitely a little complicated with that shared 4-5 cylinder port. Would have made more sense to go your way.

I had fun with the intake, i made a complicated off angle cut on a 617 intake and slid the factory end down so i would have all the same port provisions, came out pretty neat
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  #48  
Old 04-02-2020, 03:24 PM
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Any issues with the welding holding up?

I was able to get a forum member to braze the exhaust manifold for me, but it was definitely a little complicated with that shared 4-5 cylinder port. Would have made more sense to go your way.

I had fun with the intake, i made a complicated off angle cut on a 617 intake and slid the factory end down so i would have all the same port provisions, came out pretty neat
Dude. Let’s see some pics! It would really help the rest of us(especially the silent lurkers who are all considering this mod).
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  #49  
Old 04-02-2020, 06:09 PM
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Dude. Let’s see some pics! It would really help the rest of us(especially the silent lurkers who are all considering this mod).


heres how the exhaust turned out (its missing one bolt hole that got brazed on) you can see how the manifold is arranged. I cant recall what source vehicle this was out of, but probably an 83 300D
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TURBO'ing a 240D - Is it possible?-exhaust-after-copy.jpg   TURBO'ing a 240D - Is it possible?-exhaust3.jpg   TURBO'ing a 240D - Is it possible?-exhaust4.jpg  
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  #50  
Old 04-02-2020, 06:12 PM
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and intake, I made this cut in order to keep the same air cleaner brackets, alda line, and to be able to tap for boost using the casting boss from the missing automatic transmission bolt hole

It almost met up 100% for welding, but we needed to add a moon shaped sliver to the back side
Attached Thumbnails
TURBO'ing a 240D - Is it possible?-intakeweld1.jpg   TURBO'ing a 240D - Is it possible?-intakeweld4.jpg   TURBO'ing a 240D - Is it possible?-intakeweld5.jpg  
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  #51  
Old 04-02-2020, 06:21 PM
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Some good looking welds there.
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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.
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  #52  
Old 04-03-2020, 01:20 AM
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Any issues with the welding holding up?
I used silica bronz rod and a tig welder. (Preheated the manifold slow cooling while tapping on it)

What ever the exhaust manifold is made of it puddled very nicely, was just like welding steal. No issues after 80+K miles on it.
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  #53  
Old 04-03-2020, 12:15 PM
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Thumbs up

Well done ! .
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  #54  
Old 04-03-2020, 01:54 PM
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Welding really is the way to go.

What sort of work had to be done for the exhaust pipe to fit the manifold? (apologies if terminology is off... not my area)
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  #55  
Old 04-04-2020, 01:14 PM
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Welding really is the way to go.

What sort of work had to be done for the exhaust pipe to fit the manifold? (apologies if terminology is off... not my area)
If you modify 300D manifolds, none. Bolts on like stock. (Although clearly you need a turbo engine downpipe)
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  #56  
Old 04-04-2020, 04:33 PM
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Down-pipe, that’s the part I was referring to.

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