somerset exhaust fitting

[ianwalter]

I’m carrying out a complete refurbishment of my Somerset. I wonder if anyone can advise the best way to seal the manifold / front exhaust pipe joint. I’ve fitted a new exhaust (from Earlpart) and gasket, but there is a slight leak – it is impossible to reposition the pipe to get the flanges absolutely parallel because it fits through a tight hole in the chassis. Would two gaskets (to give more compression) or an exbaust sealer such as gungum possibly do the trick? Ian.

[tavistock]

I always use an exhaust paste when assembling at the manifold end. I have found modern repro exhausts to be not exactly right (or rather way out) so fitting is made doubly difficult. Not sure about the Somerset, but I jack the downpipe into position which allows you a pair of hands to fit the clamp.

[ianwalter]

On further inspection I’ve found that the leak is not at the gasket but from a small crack in the manifold just above the flange. Anyone got a spare manifold, or any suggestions how to repair mine?

[christal56]

Hi, for a quick fix until you can secure a new manifold have you considered brazing over the crack with a gas torch and some flux coated brazing rods? Make sure the manifold is clean, and you may need some extra heating time for such a big lump of metal before the brazing rod flows smoothly.

[number5]

Hi-brazing certainly is a good means to provide a permanent repair. However, before applying the required heat, I strongly advise to obtain at least a flat piece of 4″ x 4″ x 1/2″ angle, then using every bolt hole in the manifold, ensure that each section is secured to the angle to minimise the chance of distortion. The crack area must be buffed back to bright metal, with the crack slightly V’ed if possible. If a brazing torch is not available, still bolting the manifold to the angle for stability, cast welding rods may be able to be used. Again, the V prep should be put in, and before welding, gently warm the manifold before welding. Allow to cool naturally. I have successfully used both methods over the years.

[Author]

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