M20 Adaptor plate for 524td manifold?

[MonkeyMadness]

So I know everybody just notches and bolts the thing on but....
and it works well for them... but...

I bought a really nice manifold awile back from a nice guy here on the forum for a nice price. and the thing look new.. really nice..
So I'm due for a smog check in january and I'm preping my car for the
after smog turbo change over..
took my manny into work to do the mods needed and I reallized just how sketchy the mods made the manny mount on the bottom bolts...

I did not like how the bottom bolts were only a half mount, and put a few of them quit close to the runners.
So i took some mesurements and drawn up my idea for a good flange mount that allows you to bolt it properly..
then cut them out on the laser table.

let me know what you guys think.. I plan on finishing and using them
and I made them easy enough to replicate in volume "if needed" for cheap..

[MonkeyMadness]

Now these are just a first rough build..
how it bolts up is quit easy...

the top bolt hole shares the stock hole as before
the bottom hole that lines up with the manny is smaller in order to drill and tap witch will get a stud threaded in and then tiged from the back side, the other hole lines up with the head stud that will need to be removed
and replaced with an counter sunk flat head allen bolt..
the hole will also be machined to fit the counter sunk bolt
quit easy.
I don't have the bolts yet, there on order and should be here some time this week..

[Aptyp]

interested... I've had a td manifold laying around for quite a while... show mounted?

[MonkeyMadness]

the countersunk bolt will end up being flush when mounted..
the material is 5/16 and I would not go any thiner
If anything I would go thicker but you have to remember you'll
be running two set of gastkets at about 1/16 thick..





I'll be pposting more pic's as I get closer to finishing it...

[MonkeyMadness]

interested... I've had a td manifold laying around for quite a while... show mounted?

Not quit there yet...

But I will be posting them as soon as I'm there and along the way...:D

[einstein57]

If you center the exhaust flange in the center of the exhaust port instead of on the top hole its not so bad. Then you won't have to port the hell out the manifold either. You'll need the I gasket to make your template. Food for thought.

[MonkeyMadness]

see that's the beauty of it... you don't have to do any porting to your manny at all..
it's done to the flange

I used the I gasket to draw up the flange pic 4 and 5 in the first post..

[einstein57]

Sounds cool.

[MonkeyMadness]

Ok quick update..
Scored a loner moch up head from (whodwho) Keith today
after work. So I'll be draging it to work tomorrow to do moch up
the adaptors and manifold to make sure all my holes are lined up before
I start giving these things out like free candy...lol

I should have pic's tomorrow ... ;)

[MonkeyMadness]

UpDate:

Good thing I borrowed a M20 head...
Cause I done screwed up... j/k
But it's a easy fix

Ok head as it sits in the car Or on the bench...


Lower exhaust studs removed...


Flange/adaptors instaled....


I had to use some button head 8mm bolts I had laying
around beacuse those damn flat head allens haven't shown up yet
but these will work for a mock up...

[MonkeyMadness]

so after all that I slide on the 524td manifold to make sure everything is where it should be...
And They weren't ..... crap..

Picture of manifold bottom hole w/ flange hole off center...


So I grabbed some machiest die and sprayed the hole
to get an exact location. But just to be safe I used a transfer punch
to show the center of where the hole should be...


But this is an easy fix a few measurement and a bit of cad ajustments
and sure enough I'll be bolting up boost...

I'll post more pic when I cut the new flanges
tomorrow or monday...

[Aptyp]

god damn it, monkey... Gonna make me want to sell my manifold.

[MonkeyMadness]

god damn it, monkey... Gonna make me want to sell my manifold.

I don't follow you sorry..
Please explane...

My kit should be cheap as shit if you may be looking into this...

[Aptyp]

i was really excited about it working out the first time... I'm heart broken, until you fix this, lol

[MonkeyMadness]

i was really excited about it working out the first time... I'm heart broken, until you fix this, lol

Ahhhh
Sorry alittle slow tonight,, A few jack~n~cokes and I lose all......