rusted exhaust manifold

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stan

The exhaust reciently rusted off the manifold of my catalina 30 at the flange on the manifold. I have tried to remove the manifold by undoing all of the screws that I could see. The manifold will not release itself from the engine. Is there any way to get it off? Do I just need a bigger Hammer? Thanks for your input.
 
Mar 31, 2004
36
- - Mt. Sinai, NY
Visit Home Depot and pick up a one gallon can of WD40 for about $10. Fold a cotton towel so that you can wrap it around the manifold and press it up against the engine. Hold it in place with plenty of duct tape. Make a drip tray from several thicknesses of aluminum foil and place it beneath the towel. Soak the towel with WD40. Telephone Catalina to order a new manifold. You may wish to ask them how many bolts are used to attach the manifold to the engine so that you will know whether you have gotten all of them out. During the three weeks it will take Catalina to fabricate a new manifold, visit the boat frequently and keep the towel soaked with WD40. Re-use the stuff in the drip tray. By the time the new manifold arrives, the WD40 should have finished its work and the manifold should come off. When you do the re-assembly, give the bolts a good dose of waterproof lithium grease from a spray can. If you ever have to remove them again, they'll practically leap out. BTW, hang on to the old bolts. New ones don't come with the manifold. Just use some new split ring washers to keep the old bolts from from vibrating loose.
 
P

patrick

big hammer

I had an older ski nautique that the manifolds died on, you couldn't even see the bolts. we simply busted the manifolds apart with a small sledge (suprisingly brittle). Once we fully exposed the remains of the bolts and heated them with a torch a big set of vise grips eased them right out. Tip: use anti sieze when you reinstall. Good luck
 
Jun 5, 2004
7
- - Bridgeport, CT
I had the same problem. What I did was to remove the manifold from the blockcame off slick as a whistle) then Itook it to an auto machine shop, had them remove the rusted out bolts, and tap it for new bolts. Worked very well, altho I will admit that I was quite surprised that the maniford came off so easily. Kevin
 
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