DANST Engineering Self-Weld Assembly Instruction.

te ng in ee rin g. c

1) With the flange laid flat loosely assemble the tube components as per the part number on the assembly drawing, roughly positioning each runner over its flange port, Noting that the reference lines should be aligned and face downward on the manifold. All arrow head markings should point in the same direction and toward the flange.

o. u

k

Thankyou for purchasing one of our self weld kits. These instructions are intended as a guide only and the work must be carried out by a competent fabricator/welder. Please read all of these steps prior to carrying out any work.

.d

an s

2) Once you are happy with the assembly lay each runner flat (using blocks to hold as required) and tack the joint between the two components in two places – ensuring the tubes are fully butted up to each other.

w

w w

3) Each runner can now be fully welded to form one continuous tube.

4) It is helpful at this point to scribe a reference line below each port on the manifold. The distance below the port should be the wall thickness of the tube, eg 1.5mm for a 1.5mm MS wall thickness.

1

DANST Engineering

o. u

te ng in ee rin g. c

6) Loosely position runners 2 & 3 ensuring that the top of all the headers are aligned. To do this place a straight edge along the underside of all four runners (see photograph). It is advisable at this stage to offer up the carburetors or throttle bodies as a visual check.

k

5) Re-assemble runners 1 & 4 onto the flange aligning the bottom edge of each with the scribed line. Check the top section of each runner for squareness to the flange and position to each other. Once the position and squareness has been achieved tack the headers in position in four opposing places.

w w

.d

an s

7) At this stage it is possible to tack runners 2 & 3 in position. However this can be restrictive when trying to fully weld in the ‘nip point’ between the flange and runners 1 & 4. Therefore it may be preferable to fully weld runners 1 & 4 prior to tack welding 2 & 3. NOTE! Flange must be clamped or fastened to a flat, strong metallic surface prior to full welding to avoid excessive distortion due to heat. 8) Tack and fully weld runners 2 & 3.

w

9) Allow the completed assembly to cool fully before removing clamps and fasteners. A degree of grinding and finishing will be required on the inside of the join to the flange to ensure optimum flow. This should be carried out using a die grinder (or similar) with high speed steel bit and small diameter flap wheel. Likewise it is advisable to smooth the internal tube joints on each runner.

2