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[nickjaxe]

123

[V]

I only have experience with working on Land Rover engines in the bush, but the same rules should apply: the exhaust manifold should be dead-straight and sit completely flush with the cylinder head. The reason is that the exhaust manifold gets real hot, expands and if it isn't straight, the tension gets high, which eventually leads to cracks and a severely shortened life span of the manifold.

Getting the manifold skimmed straight is not difficult and doesn't necessarily require a fancy workshop. Just get a reasonably large glass plate (they tend to be level and straight), fold rough sandpaper over it and slide the manifold back and forth. It helps if you have an extra pair of hands to keep the glass and sandpaper from moving.

Another alternative is to find a straight and level concrete slab and sand the manifold against it.

Cheers,

V.

[nickjaxe]

A landrover man guess what I drive S3 88" just fitted a Disco 200 engine to it replacing the old 2.25d, own the thing from new 35 years,

Anyway back to my manifold, had a better look this morning, everything is flat but for some reason the outlet port at the mag end is set back exactly the thickness of 1 exhaust gasket further back than the PTO outlet flange but seem flat and inline,

I was thinking of just fitting 2 gaskets on the low outlet which will then be under the cowl,

I bought these cylinders 2nd hand so I dont know there history,

What do you think.

Nick.

[Duck Rogers]

Are these then not the 2 you took apart for the decoke?

I bought these cylinders 2nd hand so I dont know there history,

"Their", not "there"....

[V]

A landrover man guess what I drive S3 88" just fitted a Disco 200 engine to it replacing the old 2.25d, own the thing from new 35 years

Wow, cool! I drive a 1955 SI 86". Have a Toyota diesel ticking in it since 2004, when I did a full rebuild.

Anyway back to my manifold, had a better look this morning, everything is flat but for some reason the outlet port at the mag end is set back exactly the thickness of 1 exhaust gasket further back than the PTO outlet flange but seem flat and inline,

Huh, sounds like the cylinders are not sitting properly? Not sure of the implications, this goes beyond my experience with two-stroke air cooled engines. Hope someone more knowledgeable can comment.

I was thinking of just fitting 2 gaskets on the low outlet which will then be under the cowl,

On a Land Rover when doing a quick bush-repair, I'd say, no problem. On the long-run the 2.25 petrol would probably blow through the gaskets and would need a proper fix. On the Rotax, no idea, but doesn't feel right ...

Cheers,

V.