Cast Exhaust Manifolds (Approximately)

[Orange Crate]

After 57 years my 2.5" stock exhaust manifold cracked. Wow what a shame, these things really woke up my 406 but looked stock. Oh well on to the fix. I ordered a set of 2.5" cast units from Summit. So here are the pics comparing them to what is left of the stock pieces. I have a saying that things made in the Pacific Rim are "approximations" of the real thing. Close but.....these new ones are not going on my truck. First pic is...well yea that happened. Second pic is the "new" high performance? Third pic is the old single exhaust port. One of these things is not like the other.....On this engine I need every square millimeter of flow (No I am not going with headers). Now I am looking at the TruRam set. Anybody have a set of those? I have AC so I think these will interfere with the new Alan Grove brackets I just put on.

[Ziegelsteinfaust]

I got 2 sets of the Dorman ram horns from Summit, and they looked good. With just being rougher then factory versions, but no misaligned ports like yours.

If by true ram horns you mean the polished ones you can get from speedway that look rounded, and swoopy.

I gave my dad a set of those, and they looked very nice to me

[Orange Crate]

Thanks for the input I'll have to call them about the port size/design. I was looking at these as a substitute for the original Corvette manifolds. The obstruction that can be seen in the port isn't misalignment it is how they are cast. The port on the other end is cast the same way and also the other manifold in the set is cast exactly the same. It seems odd that the manifold is a 2.5" high performance unit but with a complete face plant in the port design, again it is an approximation of the real functional high performance piece. The original Corvette manifolds can flow pretty well up to about 4000 rpm which is fine for the way I build my engine to tow. I have an RV cam that is "all in" at 5000 rpm, so there is no need to have big flow numbers above that as you get with headers.

[AcampoDave]

Wow, those are even worse than the ones I had. Mine had smaller ports than the o.e.m two inchers and they cracked pretty quickly anyhow. I only have a 283 now so I just want back to oem 2". But wow those....what a shame.

[Orange Crate]

Originally Posted by Ziegelsteinfaust

I got 2 sets of the Dorman ram horns from Summit, and they looked good. With just being rougher then factory versions, but no misaligned ports like yours.

If by true ram horns you mean the polished ones you can get from speedway that look rounded, and swoopy.

I gave my dad a set of those, and they looked very nice to me

Does your Dads truck have AC? Any pictures of the install on that truck?

[Ziegelsteinfaust]

Originally Posted by Orange Crate

Does your Dads truck have AC? Any pictures of the install on that truck?

They were used on hot rods, amd a 50's truck. None of them had fitment issues or had AC.

[Orange Crate]

A slight update on this issue. I have searched and called just about every vendor of these "reproduction" manifolds and they all seem to have the very restrictive bolt support cast inside the ports EXCEPT one....I called Corvette Central and they have their own molds for the manifolds. But just like everyone else they have casting supply issues which basically means they don't have stock. I did talk to a guy there that actually had a set on his desk for his own car and he confirmed that the ports are correct and open. I'll have to wait until the end of the month for their restock to come in. I'll believe it when I see it.... I decided not to go with the manifolds in the picture above after finding out this info from CC.

[MySons68C20]

If it were me I would braze them up and continue....I have had great success with brazing and feel it would work well for you.

[Orange Crate]

Thanks but, the strength limits of brazing (especially at higher temps) is why I will stay away from that option.

[Orange Crate]

Ok, another update. I received the cast manifolds from CC and I am not impressed. These defects are in both of the manifolds I ordered and in the same place so I am guessing that the mold is the cause, maybe not? The concern is that the porosity will cause cracking during heat cycles. The pick is pointing to the deepest "pit". This area sees the highest temp and gas velocity so probably the absolute worst place for any kind of defects, pitting, porosity. I guess I could look for a foundry in the US that can cast these with better quality? This isn't high technology, casting iron is probably 1000 years old? Why can we not do this in this country anymore?

[cadillac_al]

Maybe send them back as defective and they could send you a better set? They can't all be low quality casting can they? I wouldn't be happy with those either. If CC only has low quality castings then I would look for good used ones on ebay and grind that hump out of them and maybe port them too.

[Orange Crate]

Originally Posted by cadillac_al

Maybe send them back as defective and they could send you a better set? They can't all be low quality casting can they? I wouldn't be happy with those either. If CC only has low quality castings then I would look for good used ones on ebay and grind that hump out of them and maybe port them too.

Yes, I started the process to return them, but they are already out of stock (within a week). I'll have to wait another six weeks to get replacements. I'm guessing that they only cast a very small number of these at a time. I predict that the replacements will be just as bad or worse. There isn't anyone at CC checking the "quality" of these parts, they come in the door from china and ship right back out to customers. Also CC does not care, they said " return them or don't, that's it"

[Willshook]

A few things.

Almost all casting is done outside of the US given the looser regulations.

Are you worried about the casting flaws ending up in failure of the part? I don't see anything in those flaws that would lead to a crack. I wouldn't be worried about anything like exhaust velocity or flow...anything other than a bone stock mild SBC is going to want more scavenging that even the best stock-type casting can deliver.

There are "hot rod" style cast manifolds that are pretty and have better flow - Sanderson and I think Hooker make these.

Finally, obviously there are a ton of these available used...and headers are obviously a choice

[Orange Crate]

Originally Posted by Willshook

A few things.

Almost all casting is done outside of the US given the looser regulations.

Are you worried about the casting flaws ending up in failure of the part? I don't see anything in those flaws that would lead to a crack. I wouldn't be worried about anything like exhaust velocity or flow...anything other than a bone stock mild SBC is going to want more scavenging that even the best stock-type casting can deliver.

There are "hot rod" style cast manifolds that are pretty and have better flow - Sanderson and I think Hooker make these.

Finally, obviously there are a ton of these available used...and headers are obviously a choice

The pictures shown above do not really show the true depth of the porosity. The picture with the pick is pointing to the deepest pit and it is deep. Again I think that this could definitely be a source for cracking during heat cycles. The 406 I built really woke up when I changed over to the 2.5" outlet manifolds from the stock 2" so I know that flow for this engine is critical to getting the most out of it. I had port matched the 2.5" manifolds before installing them. The Dart heads will flow a lot more but I like a stock look so....Again, not doing headers....