Well spent some time working in my garage, vs working on my garage.
Land Rover had a warped exhaust manifold, and was blowing out around the 1st and 5th cylinders. Was getting worse, so decided to tackle the project before it gets too hot here. Had a good friend come around to give me a hand also.
Lots of ancillary bits to be removed before I could even get to it, but not too hard. Spent a few days spraying the nuts with penetrating spray. Finally could put off the dreaded removal of the bolts any longer, so dove in. Front top sheared off immediately at the surface of the cylinder head. The #5 cylinder bottom stud sheared off at the surface of the manifold, leaving about 8 mm of stud sticking out. That one was able to get out with two nuts locked down tight, and unscrewed from the cylinder head.
Was able to use a punch and mark the centre of the sheared one on the top of cylinder #1. Drilled a small pilot hole through the stud, and then progressively larger. Finally used a star bit and tapped it into the hole. Was able to back out the rest of the stud on the end of the star bit. Big sigh of relief!!!
On inspection of the manifold, it was warped by at least 3.5 mm. Too much to hand sand down, so off to an engineer to get skimmed. 2.5 hours later, was on my way home, and a nice flat surface on the manifold.
Planning on getting it put back together on the weekend. Hope no issues with the rebuild.
1st photo: Manifold still in place, and attached to turbo.
2nd photo: Drilling out the broken stud. Note the carbon on the cylinder head from blowing out from the #1, and #5 cylinders.
3rd photo: What I had to do to hold ancillary items out of the way.
4th photo: Flat surface on the manifold again!