08-04-2006, 07:45 PM
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Join Date: Jun 2005
Location: Norfolk Virginia
Posts: 474
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Hmmm, I am not the only one I see...
Mine was the same, however I have no advice to offer. Seems strange that Italians could get it right, but a major aftermarket exhaust company had a problem like this. I thought mine was isolated.
When I showed my muffler guy, he said "eh, grind down the excess lip, and bolt it up, the stainless pipe will bend." But I don't know how that thought process goes hand in hand with Cast Iron manifolds. Also to note my Exhaust guy will not change my manifolds, I have to do that myself. He does not want the trouble of broken studs should that happen I assume. I am still having him install my system next week, to make sure it goes in right.
He has major experience with this stuff he does alot of Custom Stainless and Magnaflow systems, the steel will bend according to him.
__________________
James Hochmuth
1970 GTjr
2000 Lotus Elise 111S
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08-04-2006, 08:02 PM
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Join Date: Mar 2004
Location: Wichita, KS USA
Posts: 201
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Well, I guess that's comforting to hear. I'm going to look harder at things tomorrow and see what I think. I want it to work, just don't want a cracked manifold down the line (this is the second time I have accessed the flange bolts, first because of a cracked manifold, and I want it to be the last as my patience and knuckes can't take it again!). If others have made it work I'll just cross my fingers and drive it. I could try to heat it and straighten things a touch (have an oxy torch), but don't want to if it's not necessary or some other method is better.
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08-05-2006, 07:08 PM
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Join Date: Mar 2004
Location: Wichita, KS USA
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Slight correction to my situation - upon closer measurement this weekend, I find that my flanges are indeed parallel but slightly offset. I'm still worried about the stress that will place on the iron headers, but it's a simpler situation to sort out I hope. Does anyone know whether there's a thicker gasket or some sheet that I could cut to make up the difference? It's substantial (about 1/16") so I don't think the thin copper will do the job, but if there were something thicker I could get I could easily cut a new gasket for the once side. Any ideas?
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08-06-2006, 10:31 PM
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Admin
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Join Date: Nov 2002
Location: Santa Clarita, CA
Posts: 4,596
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Hey guys,
Just got back in town and was away from any internet connections for the last week. Boy talk about withdrawals.
I'm not an expert enough to tell you if the unevenness is acceptable or not. I'll have to contact the guys at MAGNAFLOW and see what they think and what course of action they recommend. I'll let you know.
YES the stock manifolds are very fragile. I cracked my #1-4 manifold on a prototype that had too long of an extension coming out of the flange where it mates into the manifold. It should be close to 1/8" but the prototype I had was close to 1/4" When I torque the hardware it cracked. This however is a totally different issue with the flanges being tilted and not on plane.
I have a system on my car and have only opened one other box for photo purposes. They are really packed well for shipping so I don’t really want to go opening all of the remaining systems if needed but I will if I have too. I'll let you guys know what’s going on ASAP and hopefully some others that have received the systems will post their comments.
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08-07-2006, 07:31 AM
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same misalignment as photo on page 4, I am considerding cutting flange off, cutting at the 1/2 mark on the small OD behind the flange, small sleeve, install flange and bolt both flanges up to heavy flat stock, with correct bolt pattern and welding the sleeve top and bottom, then after removing from jig, welding and grinding the inside. if the thicker OD behind the flange interfers with the bolts. cut 1 flat off and weld to the flange. but will wait for now.
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08-10-2006, 12:51 AM
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Join Date: Nov 2002
Location: Santa Clarita, CA
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Hey guys,
I've been talking with MAGNAFLOW and some other vendors and the offset between the flanges is definitely supposed to be there. The offset should be about an 1/8" from my calculations. The flanges should be on the same plane but with the mentioned offset.
Some of the flanges appear to be tilted but that is only because the nipples or extensions coming out of the flange are sometimes cut at a slight angle giving the appearance of an off center flange as seen above. If you get out a measure you will see the flanges are right on plane. The uneven nipple cut has no effect on performance and the nipples are mostly there to help with gasket alignment. If wanted they could be grinded off all together.
If you are having any other problems other then the two mentioned above please feel free to email me or post here (images help a bunch) to the thread but please don’t start cutting and re-welding your systems.
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08-10-2006, 06:50 AM
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Join Date: Mar 2004
Location: Wichita, KS USA
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Awesome! Thanks for the update, Simon. I'll be bolting things up tonight - can't wait!
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08-11-2006, 07:10 AM
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Join Date: Mar 2004
Location: Wichita, KS USA
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Got it all together and it's sweet! After careful and repeated measurement of my header flanges and the exhaust flanges, I concluded that there was still some slight offset to make up which I did using one thin copper gasket and one thicker graphite gasket [the exhaust had 1/16" offset while my headers had none]. The good side got the copper, and the side with the gap got the graphite. Tightened it all up last night and ran it for a few minutes, and no leaks found. Everything else all the way back lined up perfectly. I also took some time to progressively sand the tip down (400, 600, 1000 grit) and then polish it - looks great!
Congrats on a great design and good price Simon!
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08-11-2006, 10:10 AM
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Join Date: Apr 2003
Location: S. California
Posts: 210
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If you get a chance; please post some pictures.
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08-11-2006, 10:30 AM
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Join Date: Mar 2004
Location: Wichita, KS USA
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OK, I'll try to shoot a few next week. I did the work on ramps, not a lift, so there's not much to see, but I'll try to get a few decent ones.
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08-11-2006, 10:32 AM
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Join Date: Feb 2005
Posts: 47
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Magnaflow SS sytem
My '67 GT was fitted with the shorter version for headers (the GTA type in my case) resulting in excellent fit, in fact, the tailpiece has the ability to rotate by loosening the relative clamp in order to position it as you need in the rear body cut out below the bumper. The sound is back to what an Alfa should have only with a throatier note and the motor just breathes so much better. I have a performance built 1600 that is certainly happier with this new system!!! I will have a dyno run result shortly to compare to the previous Super Sprint system Magnaflow replaced. More to follow.
Rich
'58 spyder
'67 gt
'65 gta
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08-11-2006, 03:18 PM
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Super Moderator
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Join Date: Nov 2002
Location: Northridge, California
Posts: 6,028
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Anyone in the Monterey Bay area want one with free shipping? I will be there this Sunday (8/13) so I can bring one up if you meet me at Laguna Seca. Lemme know.
__________________
Anthony Rimicci | 64 Giulia Spider | 65 GTA | 68 GT Jr.
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08-15-2006, 03:53 AM
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I managed to take a few pictures of the flange offset that some have been commenting on.
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08-15-2006, 06:04 AM
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my problem was more like the photo JeffM posted on page 4, the flanges are on two planes, as in the above photos posted by Simon, but the planes were not parallel, the outer edge of the first tube being level with the second tube, the inner edge being lower, the result being that the tube didn't mate up parallel to the exhaust manifold. I will be checking that exhaust gasket regularly.
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08-15-2006, 07:22 AM
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Join Date: Mar 2004
Location: Wichita, KS USA
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 Quote:
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Originally Posted by alfa of-corse
... flanges are on two planes, as in the above photos posted by Simon, but the planes were not parallel...
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When I put a ruler across the higher flange, just like Simon shows, in the center, it found that the two flanges are indeed parallel but just a bit offset. So disregard my photo and pretend it looks just like Simon's above, which it actually does. I bet yours does too.
I did not find that my manifolds on the car had the same offset (nor did the previous OEM 2-1 front pipe that I removed). Don't read too much into that, though, as my manifolds are not a matched pair anymore. One cracked a few years ago and I replaced it, leaving the other alone. So one of mine is from 1974 and the other is from a later unknown year. That probably accounts for my slight difference from the normal offset.
In any case, I found a thick similar shape gasket at the local auto parts place and used it on the side that needed it. No issues so far, though I have barely driven it at this point. I also found that one could buy 1/16" thick exhaust gasket in sheets on the web and cut to fit, which was my backup plan.
I'll try to take some pics tonight, but it's all bolted up now and pics of the flange area won't be easy to get since it's close quarters in there. At any rate, I finally concluded that the offset is OK and if you have any mismatch it's probably equally the fault of the headers and the simplest thing is to make the adjustment in the gaskets. I thought about having a machine shop skim the flanges to adjust, but why do that when a $1.50 gasket is just as good and a whole lot faster and cheaper?
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