Exhaust Manifold Studs And Gaskets Etc...changing Turbo To A Highflow

[LTHLRB]

im doing my new engine, need to replace studs and gasket.. i know its going to be a bitch as the last engine was a whore.. i will update you all on how many i break and whos balls i break to get them out lol

[noone]

Just wondering if anyone can give rough prices on these gaskets and studs, more so gaskets, am looking at updating turbos soon and wondering if the HKS kit with all the gaskets & studs included might be worth it If I can get it cheap enough compared to the garretts wher you have to supply your own?

[MANWHORE]

Those hks kits are a good thing don't get me wrong, but they're pretty expensive.

Studs are like $2 each or something like that from nissan.

The gasket is $40 from nissan.

copper washers are aobut 10c each.

[Wheezy]

Just use an RB30E manifold gasket and chop it up into the 6 individual ports to fit the correct way....cost $8

[noone]

Thanks Manwhore I guess its not the "kit" part that makes up the extra price with the HKS gear then!!

Didnt realise the gaskets were that cheap

[benl1981]

Used drills and reamers to enlarge the stud slots in the manifold (would have been better with die-grinder - but bunnings wasn't open).

What a c..t of a job.

All looks good now - machined manifold sat flush against head. Almost all back together. Will get some new sparkies tomorrow while piping is off.

It appears the manifold was out from the factory. You could see where all the yokes (spacers) had been sitting and there were a few of them right at the extremities of the slot, stopping the manifold from going on. Wonder if the bloke on the assembly line had to have a hammer with him... hahaha

Edited April 6, 2007 by benl1981

[MANWHORE]

Hey ben

Nah, it's hard to describe, but i'll try my best. try and visualise it. When it was new, it would have gone smoothly on, like how it does now after you enlarged the holes. The studs would haev sat where they were.

The problme is, being cast, that it warps. After machining it, the manifold is still warped. So where the holes used to be isn't where it is now. Machining it just makes it flat, doesn't unwarp it.

[benl1981]

I see your point but I doubt the yokes would have moved over time i.e. you can see they are well off centre by the mark they left..

Good point about the warping and then machining. The amount it had warped was only enough to be out by about 0.8mm end to end, hardly enough to make the huge difference at the slotted holes.. but I guess possible.

I just hope the studs dont give way again otherwise Ill be pissed.

Changing turbo + manifold removal etc takes a while. Would be quicker next time - but hopefully there isnt a next time, atleast on this car

[MANWHORE]

If you torque them correctly, and if the manifold is machined flat, it should be right. The manifold has already warped, so it might not warp much anymore.

Like I said, my car's still got the stock studs in there, and they haven't broken yet (my car has very very low ks though)

[MANWHORE]

PS: hope everything goes well with your gcg highflow. You shouldn't have any problem lining things up. The last one went on like it was a stocko.

[benl1981]

Yeah everything lined up perfect.

Hoping it isn't much laggier than stock. Will find out tomorrow.

[Drivebai]

Hey BEn,

How much has fixing the broekn stud cost you so far? including maching etc...

THanks mate.

[benl1981]

Drivebai.

Stud remover bloke: $140 including new studs

Exhaust manifold: $88 Nissan + a couple of missing washers (about $5)

Machining of manifold: $60

So just under $300

I can Pm you the stud remover bloke details. He was pretty good.

[MANWHORE]

Just to confirm, was that $140 including the price of all studs?

How many broken ones needed to be removed?

cos if that's includign the price of all studs, that's not a bad price, coz there's quite a few there, so at $2 each, it's not to bad.

Most stud remover guys charge about 60-80 just to remove 1.

[benl1981]

It was to remove 2 broken ones.

He provided the 12 studs and fitted them. Yeah for peace of mind I think it was worth it. He did ask if I had attempted to take the stud out..if so the price goes up to $230+ straight up

[MANWHORE]

That's not bad actually.

that's $24-36 ($2-3 each) worth of studs.

Then a $20 callout fee.

So he charged about $50 to remove each stud. Thumbs up.

Did he use easyouts? or did he weld onto it? From you watching, did it seem like the broken bits of stud were wedged in tight (easyout almost snapping) or were they quite loose?

[Drivebai]

Hi Ben YEs please pm me his details.

He is in Sydney right?

Thanks mate