I understand everyone's concerns with the welding the manifolds. It's a last ditch effort to make this all work. This is why I'm asking so I don't junk these manifolds. You guys have the experience to help me avoid that. I appreciate the feedback.
Instead of welding them to the adaptor, why not index them to it using locating pins. Use longer bolts and custom hold downs, then let the locating pins hold the manifolds in place. The problem I see with the whole welding process is heat expansion. That much cast iron is going to move around after welding from heat of the exhaust and something will give way.
Maybe you could bolt the manifolds to the adaptor from the back side with recessed bolts, them bolt the whole assembly to the head with factory mounts. Or, see about a oversized water jet cut flange so you can bolt around the edges.
I just don't see weld as a very good option when then are other ways of getting there.
Joe,
I really like this idea! I could use countersunk bolts on the backside to attach the manifolds to the flange. Theres enough surface area on the intake to do this. My concern is that on the headers, theres only one ear per runner to mount to. Do you guys think that would be enough clamping force to avoid leaks?
