Feeler: OM606 Exhaust Flanges

[Simpler=Better]

Would there be in an interest in solid one-piece flanges for the 606 to make your own exhaust headers?

1/2" mild steel would run ~$110 shipped CONUS

3/8" 316 SS would run ~$140 shipped CONUS


I'm looking for a minimum of 4 people who would want in on it to be worth the setup time.

Anybody interested?

[KarTek]

Here's a couple thoughts:

I made the flanges for my experimental manifold out of 1/2" stainless. I machined them from raw plates using a combination of band saw, drill press, hole saws (several which wore out from cutting the stainless), plasma cutter and vertical mill.

This was an incredible PITA, so looking back, I would jump at the opportunity to get the flanges for $140 or some more for the 1/2".

Another technical problem I have not overcome yet is the funnel shaped collectors. I have yet to figure out a simple way to produce them.

Finally, welding to the flanges tends to distort them so it's a challenge to get them flat after the fabrication is complete.

To sum up my thoughts on this: My goal for the custom manifold is to get it done for less than $1000. I think this is a realistic goal using a combination of my own work and custom parts. As it is, you can buy custom manifolds complete for other popular diesels for less than that.

Some ideas:

1/2" mild steel flange ~ $110
3/8" Stainless flange ~ $140
1/2" Stainless flange ~ $160

Add steel collector cones ~ + $50
Add stainless collector cones ~ + $80

Add proper, distortion free welding of cones ~ + $200 (I figure 2 hours of welding time x $100/hour)

If you could come up with a way to make all this happen, it would be of the most benefit to potential builders. Also, I have a .dxf file of the manifold flange if you want to experiment with it. It's a prototype so it hasn't been refined yet.

[Simpler=Better]

Originally Posted by KarTek

Here's a couple thoughts:

I made the flanges for my experimental manifold out of 1/2" stainless. I machined them from raw plates using a combination of band saw, drill press, hole saws (several which wore out from cutting the stainless), plasma cutter and vertical mill.

This was an incredible PITA, so looking back, I would jump at the opportunity to get the flanges for $140 or some more for the 1/2".

Another technical problem I have not overcome yet is the funnel shaped collectors. I have yet to figure out a simple way to produce them.

Finally, welding to the flanges tends to distort them so it's a challenge to get them flat after the fabrication is complete.

To sum up my thoughts on this: My goal for the custom manifold is to get it done for less than $1000. I think this is a realistic goal using a combination of my own work and custom parts. As it is, you can buy custom manifolds complete for other popular diesels for less than that.

Some ideas:

1/2" mild steel flange ~ $110
3/8" Stainless flange ~ $140
1/2" Stainless flange ~ $160

Add steel collector cones ~ + $50
Add stainless collector cones ~ + $80

Add proper, distortion free welding of cones ~ + $200 (I figure 2 hours of welding time x $100/hour)

If you could come up with a way to make all this happen, it would be of the most benefit to potential builders. Also, I have a .dxf file of the manifold flange if you want to experiment with it. It's a prototype so it hasn't been refined yet.

Thanks for the feedback, I might make up one or two and leave them on eb*y

The transitions seem to be pretty easy by hand if you have an oxy-acetylene torch and a big hammer. If there really was interest I could look into making up stamping dies.

Side note-Is stainless really preferred? I've always heard that mild does better with constant heat cycling.

[mytmousemalibu]

If you can do a 1/2" 304 SS flange, thats what I want and would buy one from you in the near future. I say now but gotta get back to an employed status first!

I have not heard that about mild steel VS stainless as far as heat cycling. I just don't want a dissimilar metal junction. I would hope that 1/2 stainless will hold up fine. Most high quality stainless headers have stainless flanges including some of the very expensive stuff on high end race cars. Take a look at Reid Washbon's stuff, very nice but very expensive! They can build you an inconel header if you need. They do happen to have some very nice transitions but i'm sure a nice price too. I planned on making those myself with a forming mandrel and hydraulic press.

[KarTek]

So, I'm getting fed up with struggling with a design and I'm probably going to abandon the existing design for a different approach. I'll be in the market for the 1/2" mild steel version soon!

[Simpler=Better]

I'll get back on the game then

[atypicalguy]

Ok guys whats the status?

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[KarTek]

Well, I'm just about finished hooking up my new (to me) TIG welder so I can put the rest of the manifold together.

S=B needs to get on the stick!

[Simpler=Better]

Si...ug...I forgot about this completely!

PM me in a week if I don't post back with an update *ducks*

[KarTek]

Right now, I predict my need for the flange will be in about a month. I'm fabricating the exterior parts first and then I'll join them in one piece to the flange.

[atypicalguy]

Ok whats the latest

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[Simpler=Better]

Gotta clean up the CAD file and then get time to run them. Probably two weeks-ish out.

Only like 5 billion other things in real life going crazy at the same time. business as usual

Going with 1/2" mild steel, it's cheap & strong.

[atypicalguy]

Send it. Tell me your PayPal and how much again.

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[atypicalguy]

Did this ever become reality?

Does anyone know what diameter tubing will stretch best to fit the oval holes?

Thanks.

[KarTek]

I'm still holding my breath, turning blue...