Hi, this one seems a bit bizarre.....

I am in the process of installing a super-six intake/exhaust manifold onto my 1970 Dart Swinger's 225....and upon doing a "test fit" of the exhaust manifold onto the head, I am finding that the exhaust manifold does not line up with the studs on the head!

It comes VERY close. What is not quite lining up is the two outer-most studs with the outer-most holes on the manifold casting. I've matched up the "new" super-six exhaust manifold to the "old" single-barrel exhaust manifold, and they seem to line up just fine with each other, as far as the ports go. But the two outer-most stud-holes are a bit off, relative to each other.

Granted, the "super six" setup is a newer setup than the intake manifolds that existed in 1970, but shouldn't the heads be the same???

I bought this super-six setup on ebay, and am unfortunately unaware of the year vehicle that it came off. As such, I suppose it is entirely possible that this super-six setup came from one of the hydraulic camshaft engines from the 1980's....if this is the case, can it be used at all? If I opened up the holes on the outer ends, could this be used?

I guess I am looking for a some guidance here.....yargghhhhhh

I think I would be a little less frustrated if I hadn't just sandblasted and re-painted these parts.....lol. hahaha....okay, anyway, I need to sort this out. Hoping that this makes sense to you guys!

thanks slanters!!!!

Check to see if the studs are bent. Maybe the manifold is a bit warped?

Yeah, it shoudl bolt right up. The holes in the exhaust manifold should be oversized and the stud may not be exactly centered (when cold), but it should still go on without any problem unless you're dealing with some serious warpage.

everything looks as straight as can be. the outboard holes are a bit smaller than the ones on the old one-barrel counterpart, but not by much. This flat-out refuses to bolt up!

hmmmm

any thoughts on how to enlarge holes in cast iron!?!?

in all seriousness, can I drill those holes out with conventional hardened drill bits?

this is so strange.....

thanks for your continued thoughts/support!!!!

If you are not drilling out the manifold you could go down one size on the stud. You could have a machinest take a high grade bolt that fits the head. pick a bolt that has only enough thread to go into the head. The machinest could turn it on the lathe. The new smaller bolt shoulder would have a short amount of threads (turned by machinest) on the end to accept the next size downward high grade nut.

Maybe someone sells a stud that reduces and you could just buy one.

Just tourque within reason. It would work fine but tourque evenly modest amounts at each tightening until all larger studs are fully torqued. Then bring the new ones up to within a few pounds. gl440

You can easily drill out the front and back exhaust manifold holes with conventional drill bits, yes, and aside from a better-fitting manifold, this is your best option. I would definitely not use a smaller-diameter-than-stock fastener!

You may want to check the alignment of the manifold with the gasket. If there's an alignment problem with any of the ports or stud holes, I would complain to the vendor of the exhaust manifold, for it would at that point be obvious that the manifold wasn't manufactured correctly.

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Too many people who were born on third base actually believe they've hit a triple.

Thats why we pay Dan the big bucks. He, is of course, correct.

HOWEVER IF, there is a lack of strong material and cannot be drilled the other will work.

It would have a shorter life span. It would however work, and work well.

Maybe change them out after a couple years due tu heat, rust etc..

It would work quite well but if there is meat to drill I agree with Dan.

Dan, He knows his stuff.!! (integrity comment intended)
LOL, and with Merry Christmas in the air.