Exhaust Manifold Smoothing Kit

CONTENTS OF THE KIT

IMPORTANT SAFETY GUIDELINES

• - Wear eye protection such as our Full Face Mask (13123) or Goggles (43090) at all times when using carbide burrs or abrasive rolls.
• - Always wear a properly fitting Dust Mask.
• - It’s better to scrape away old gaskets that may contain asbestos than to use abrasives on a power tool. This will reduce the likelihood of getting asbestos particles in the air!
• - Do not wear loose fitting clothing. If your hair is long, tie it back.
• - Clamp manifold firmly to a bench or place it securely in a vice.
• - Use minimum pressure against abrasive for longest life and to avoid bending mandrels.
• - Do not use abrasive rolls or carbide burr in excess of 22,000 rpm!

INSTRUCTIONS

• See owner’s manual for proper procedure for exhaust manifold removal.
• - Degrease manifold with a heavy duty degreaser such as Metal Wash (10120), or PRE Painting Prep (10041Z)
• - Wear disposable gloves, like our Disposable Nitrile Gloves, to avoid contaminating the cleaned surface.
• - Examine manifold for obvious defects, such as pinholes, warpage, or cracks. Replace or repair defective manifolds before smoothing.

Using a Carbide Bead Burr (comes with Deluxe Kit)
A carbide burr can speed your work by quickly leveling rough pits or casting flash. Keep the spinning burr moving when in contact with the surface to avoid creating an uneven surface. Exercise care not to cut through the casting wall on older severely rusted manifolds.

TIP: If you are using a pneumatic die grinder, regulate the air pressure down to the desired speed so that the trigger can be completely depressed, assuring a secure grip and better control of the tool.

Using Abrasive Rolls
Smooth the manifold using the die grinder with the included 4" mandrel and 80 grit cartridge rolls and tapers. If you used a carbide burr to begin the smoothing process, work the 80 grit cartridges at about 90° to the previous burr scratches.

TIP: Using 60 grit flap disks on an angle grinder can speed up smoothing on large, flat surfaces and curves. They are available in 4" and 41⁄2" sizes.

NOTE: Exercise care to avoid damage to gasket surfaces. Eastwood’s Gasket Cleaning Kit (46055) is ideal for removing old gasket material without damage to the surface. Caution: If the old gasket material contains asbestos, use paint remover and scrape by hand to prevent asbestos from becoming airborne. Dispose of asbestos material in accordance with local regulations.

NOTE: If you plan to match the cylinder head exhaust port to the gasket size: current high performance engine building practice indicates the exhaust manifold opening should be larger than the cylinder head exhaust ports to create a step that inhibits exhaust gases from flowing back into the combustion chamber. The Eastwood Porting Kit (46056) provides complete details.

• Once the pits have been smoothed out using the 80 grit cartridge rolls go over the 80
   grit scratches at right angles with the 120 grit abrasive rolls until all 80 grit scratches
   are removed and blend in surrounding area.

Final Preparations for Coating
• Any remaining rust can be removed by abrasive blasting.

TIP: If you wish to impart a natural rough sand castle look to the smoothed surface, try this technique: use a piece of 36 or 40 grit sand paper to hold against the surface and gently hammer to transfer some roughness to the surface.
NOTE: If using rust remover, be sure to check manifold every 20 minutes and remove rust remover when part is rust free. Leaving manifold in contact with rust remover longer than necessary will damage the manifold.

• Wash manifold with and allow to dry before coating.

• Follow directions on can of high temperature manifold coating for satisfactory results.

Eastwood provides durable manifold coatings in four colors: Satin Black, Factory Grey, and Silver.

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