Technical Can I repair this manifold without milling?

Engine experts - can I repair this manifold without having to get it milled?



Here's the back story. Saw a good deal on craigslist, had it shipped and it showed up looking like this. The mounting hole is ovalized and the gasket surface is no longer flat. Local machine shop says they can mill it. If I can, I'd like to repair it myself without milling and save some coin. Would it work to use a drill press to re-center the hole, and carefully use a file to take down the "lip" There is the risk that filing won't be flat like milling, but it would be on the outer side of the mounting hole.

Thoughts?

 

Looks like if you take your time you could fix it with a file. And the hole.

 

I'd use a file to fix it, both the hole and the dent. No biggy.

 

Bigger the file the better.

 

Don't try to drill the hole unless the manifold is secured to the drill base as it will walk and oblong the hole the wrong way.
^2 I use a round file in the hole and a fine flat file for the surface, chamfer the hole slightly after your done and you will not tell. your wallet will thank you.

 

A large flat file, use poor mans machinist blue, (magic marker) and be careful . Round file in round hole , bolt head will cover it.

 

Drills follow holes, it will put your hole in the wrong spot, do not drill. Round file for hole then flat for surface.

 

Sometimes an old bastard can be helpful.

 

I think I would support that flange well. and drive a taper pin punch in that hole from each side. You can probably reshape that hole to round.

 

I done a similar repair in the past with a file. Go slow and be careful and it will be fine.

Andy

 

Your local machine shop should have put a file to it.
That's a 10 min job with a flat file and a round file.

 

Thanks for the replies gents. A sharpie and a file it is!

JP

Also something for the memory banks that my machine shop didn't suggest that to me.....

 

If you want to make it absolutely flat, take a sharpening stone and some WD 40 run it over the surface to feel if it drags, if not then its good.

 

No. You could crack off the edge of the casting.

Hand files only on this one. Draw a flat bastard flush to the deck surface, and a rat tail file for the hole.

 

Wrap a piece of masking tape around the tip of a nice, new, sharp, file so it won't dig in. Lay it flat on the work and do the cutting up near the handle end of the file. Watch the tip carefully so it doesn't cut! Don't push to hard, you don't want to "load" the file. When the bump is gone, the file will start to shine up a larger area, and the job is done. If you have the time you can fix a warped head this way.

 

Lots of good advice for the rat tail file to open the hole, and flat file to get the surface flat again. But don't drive anything into that hole to try and make it round again! It's cast aluminum, and driving it back out would most likely fracture the hole.
Get a good straight edge also, so once you've got the hole open you can use it to check the flat as you file.