Header Flange Needed

[KiWinUS]

Do not use brass. Bronze. Or silicone bronze to repair. Yes it will fuse/bond them together very well and can look great quite easy to do BUT has a different expansion rate and will eventually fail. I have seen this and also done it myself many times when I had no other option. Find someone that can weld cast iron correctly. Good luck.

[jeepguy1948]

Deuce, thanks for the suggestion I’ll check it out. Can you tell me is the Fenton outlet bigger than or the same as the stockers?
CA, It has to be cast iron.

[jeepguy1948]

Kiwin, I have located an outfit about 40 miles from my house that does nothing but weld cast iron to cast iron with cast iron rod. Unfortunately he has no material on hand and doesn’t do any fabrication of any kind.

[tubman]

Originally Posted by jeepguy1948

Deuce, thanks for the suggestion I’ll check it out. Can you tell me is the Fenton outlet bigger than or the same as the stockers?
CA, It has to be cast iron.

In my experience, the Fenton's have the same outlet pattern as a stock Ford manifold.

If not, you can make a new head pipe to match, especially since you intimated that there may be a problem with the original head pipe.

I still have to ask: Why is this such a problem? In my world, it would have been solved a week ago and I would have moved on to other, more important things.

[deuce_roadster]

Jeepguy1948, find "cast iron Mike" who I think now is in Everett. Rob at Action Machine in Shoreline would have his phone number, give him a call. He has a business of repairing cast iron heads and blocks. He heats them up with a big gas oven before welding with silicon bronze. I only have stock exhaust manifolds that could be sacrificed, not Fentons. Dave Tatom from Mt. Vernon who passed away last year, using a dyno told me the stock manifolds made the same hp as the Fentons for street engines.

[jeepguy1948]

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I believe that “cast iron Mike” is who we are trying to get to do the repair but I have to find a flange for him to use. I know that because of the poor porting of the V8 the Fenton’s don’t provide any horsepower gains. BUT I have had this truck since 1975, the headers were installed in 1980 when we installed the rebuilt (at that point it was built with Merc specs) engine with Finned Heads, moderate cam, dual carbs. Come hell or high water I am going to keep the Fenton headers that have been on the truck for 43 years now. If you read my above posts you will see that the drivers side header was modified to fit in the F-1, Fenton never made Headers to fit an F-1 (the steering box is in the way). Even though I am aware that the headers do not provide any performance improvements BUT THEY LOOK COOL!

[deuce_roadster]

If the flange to the head pipe on a Fenton is the same as stock, I am sure I have a good one you could cut up.
When I dealt with cast iron mike his shop was in Lake Stevens but he hasn't been there in years. He welded up a belhousing crack for me on a Ford Cut-A-Way block our Regional Group restored that is now in the Ford Museum in Indiana. There are pictures of it in one of the albums in my user area. Yeah I read all the posts from the beginning the first time.

[19Fordy]

Just out of curiosity, it would be nice to see a photo of the broken FENTON header.

[deuce_roadster]

Agree with 19Fordy.

[jeepguy1948]

I attempted to post this earlier but apparently it didn’t go thru. I am severely technologically challenged and have not been able to post pictures. What it looks like is this… If you were to look at the steel flange shown earlier in this thread, and break off one ear, that’s what I have.

[deuce_roadster]

That sounds like a very easy fix. Do you have to fit the new piece to what you have? I would think that should be left to the welder as he knows how much bevel he wants on the piece.

[GB SISSON]

I have about a dozen cast iron manifolds. I even saw one in my lower lot that has a missing flange. What is your address? It will be in tomorrow's mail. I have a 6" wide belt machine if you want it ground flat on each side.

[GB SISSON]

I go right by the broken one every evening on my cardiac walk, so I found it on the shed's dirt floor. I would think that center flange might be the best? Some of the ones in my nest of manifolds have longer stems on them but probably best to consider the broken one first. Without a photo of yours I think the 1" cut that NewC suggested is safest.

[tubman]

I think the flanges that go against the exhaust ports are smaller than the actual outlet (I seem to remember that the gaskets do not interchange). I would double check them to make sure.

[GB SISSON]

My understanding was he needed a flange to the block. He can have either one. I'm thinking the gasket is the same. The outlet flange might be more substantial/thicker. Edit: Outlet has a flapper in it, and if removed there is not really a flange per se at the common outlet. Also the forward most block flange is drilled for 7/16" studs instead of the 3/8 " on the other 2.

[CA Victoria]

There is a source for cast iron rod used to repair cast iron. They claim to have used it to restore cast iron and repair cracks. I haven’t used the rod I purchased yet but i will post the website later when I make it out to the shop.

[GB SISSON]

I arrived late to this party. I did read it through but upon re-reading I feel you need a flange for the outlet. If they are indeed the same size, how much of a 'leg' do you need, or is a double flat sided diamond shaped piece all you need?

[GB SISSON]

I have my sawzall sitting here with a good blade and I'm not afraid to use it......