DIY Conversion manifolds - Mk1 16v & maybe others (UPDATED-More Pics)

[Mk1Mad J - 16v]

One of the hardest parts of doing an engine conversion is finding a suitable exhaust manifold, there are some available for popular applications but these are usually expensive poorly made pieces off poo!!! 

Having successfully made my own downpipe for my Mk1 16v conversion I thought I'd show others how - I don't see why you wouldn't be able to do this for any engine conversion 


Parts needed:-

Manifold - to match engine being fitted (in my case a Mk2 Kr)
Downpipe -
Downpipe - to match car
Some exhaust tubing - a tight fit over exhaust



I started by chopping the flange off the mk1 downpipe, I cut the pipe as close to the flange as possible, also in the pic is the extra bits I chopped off later.



I then cut the flange off the 16v downpipe (just before the pipe loses its shape) fitted it to the 16v manifold and offered it up to the head with the mk1 downpipe already in place.  I found that there was too much tubing for the 2 exhausts to meet so i chopped a little bit off the mk1 pipes (too much  ). then I offered it up again, it went in but was fouling the gearshift  i had to cut it down quite a bit to get the clearance as you can see in the pic.


I welded it up a bit where i'd cut but its full of some kind of mesh which the arc welder throughly enjoyed melting (lots of sparks  ) - this is about as good as i could get it   :embarassed:


It might look a mess but at least it clears the linkage 


I cut the joint end off a spare backbox I had kicking about and used it as a sleeve between the 2 parts of exhaust and it was a total success  trouble was I only had one spare back box  I called around my mates but nobody had an old backbox i could have 


  If you're wondering about the screwdriver, the pipes wanted to play with each other so I wedged it in there to temporarily separate them 

I had a sleeve made (Thanks Paul  ) to join the exhaust

Just need to  weld it 










                                                        

[mk1]

Nice one, good to see someone using a bit of imagination and saving a few £Â£Ã‚£s .
Steve.

[Mk1Mad J - 16v]

I took a few under the car shots the other day, so here's some of the fitted exhaust 


Now, with some exhausts I could mention, you have to heat-shield the steering parts to stop them from melting... unfortunately the one in my loft was in actual contact with the steering rack     

This one doesn't come anywhere near the steering gear:-




No contact with the Anti_Roll bar here either 



It doesn't hit the gear linkage like other's I could mention either 




Perfect