Blowing exhaust flange.

The left hand exhaust flange on my 996 which joins the three downpipes from the manifold to the rest of the system has started to blow. On investigation, it seems that the flange has parted slightly and is blowing through the gap. The gasket is still in place and in one piece. It would appear that there are studs in place but no nuts to tighten and pull the two flanges together as in conventional exhaust. Anybody no of a quick fix remedy??

A neat weld is the answer, it can always be cut and ground back to shape at a later date if required. I would not bother trying to seperate, it is a MAJOR 3 hour job to drill the bolts out (the nuts always corrode off on these) whereas a weld takes 10 minutes and works better IMO

Hi We usually remove the old studs and use new nuts and bolts. Usually takes about 1.5 hours. Grant www.hartech.org

Showing off with your fancy drill bits! (1.5 hours)

This sounds like what happened to my car a month before I sold it. My indy took 7 hours to drill out all 6 bolts and replace the gasket. When you see the bolts you might shake your first at Porsche - they are rubbish - no wonder they snap the minute you try and undo them! My indy had to weld other bits on to them and try and get them off that way. Labour 7 hours, parts c.£14. Cheers.

Whilst looking at the cat to manifold bolts take a glance at tv manifold to head bolts then start some real worrying Sort of kills the option of pulling the manifolds off to fix the 6 nasties I would not weld the joint up seems a bad idea to me Fabricate a clamp to pull it together for now and ram in some putty to help the passing gasket.

a little update if anyone has read the other thread i posted about this.... 4 weeks since I took mine in to have that gasket removed...should get the head back on Monday with the broken manifold stud finally removed. I would highly reccomend bodging it together anyhow rather than trying to f**k about with those flange bolts as that is where my nightmare started. Still should have the car back in one peice end of next week when the engine goes back in!

Pontypool Does the engine have to come out to get the head off?

according to the mechanic it did...

Grant - I assume you leave the manifolds fastened to the heads. The flange studs look an interference fit and pressed into the flanges. I bet the studs are glass-hard steel too, as Lloyd says, you must have some fancy HSS drill bits! Nick B

We remove the studs and replace them with bolts. The manifold usually stays on the car. Bit of a trade secret how we do it I'm afraid but with the upmost respect its not a job for the home mechanic - further damage could occur if not careful and it requires some special equipment.

have the same issue, decided to do adeymars advise and putty and G clamp and see what happens, will have to replace the back boxes for the M.O.T in march so will make the system last with a bit of a patch up, when i do i think a whole new system in order, was thinking porscheshop do s/s manifold, 100 cell cat and back boxes for about £1400 plus my indie to fit? is this good value?

Baz There are no secrets on this forum so spill the beans or self promotion whilst apologizing for promoting oneself will be not be tolerated any longer Or are you able to offer a group buy Remove studs and replace from manifold to head and cat to manifold?

Adey Before I reply are those comments tongue in cheek or serious ? Grant

Whilst I am just a master and not alas, a moderator then this fact should alone answer your question bizzare as it is. So can you? Apologies for my Yorkshire wit too strong for some at times I find.