I'm going to cast an intake out of aluminum for a EFI turbo conversion for my Dart. Is it posable to also cast the exhaust manifold with aluminum? Sure would be nice to put that turbo right where I want without any type of adapter, avoid the extra weight of cast iron, and be able to copy the set up for my Valiant!
Dan M.

I'm no metalurgist, but I strongly suggest no. We have enough warpage problems with a cast iron exhaust....can you imagine how bad it'll be out of aluminum? Too much heat and length for the material. Might be better to fab one out of steel sheet and tube.

Roger

No way. Can't remember what is the melting point of aluminum, but I think is around 1000 degrees. When I used to run my turbo, the exhaust gass temp, would get up to about 1200 degrees.

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Charrlie_S
65 Valiant 100 2dr post 170 turbo
66 Valiant Signet 170 nitrous
64 Valiant Signet
64 Valiant 4dr 170
64 Valiant 4dr 225

Charlie hit it, Aluminum will melt at exhaust gas temps. (1200-1400 degrees, dependant on the alloy)

Cool idea but exhaust manifolds get too hot for aluminum.
DD

Pontiac used aluminum exh manifolds on their Super Duty engines around 1962. If there are any left, it's the ones never installed on a motor.

Cecil

I found this on the web, may be of interest:

http://www.majorleagueduning.com/tech/h ... xhaust.htm

Well, maybe an aluminum alloy exhaust manifold would work if it was water cooled, but you want the heat for the turbo. The weight savings of steel tube headers is substantial, I think a stainless alloy would be good to use.

Hey Budbandy, cool PICS on the manifold. I really like the short pipes to keep the heat high. Do you think it might be better if the bends weren't so sharp? I thought the aluminum idea was crazy, got too caught up in the thought of casting, and forgot about the heat, especially with the turbo!
For a moment I visualized an aluminum exhaust manifold melting down the side of my engine. Cool! (flashback)..I mean... Damn 60's pop art!

Guess I need to get a plasma cutter next!
Dan M.