E6 manifold

[russde]

Went to the local 'pick-n-pull' this weekend and found a 'new' car....'88 XR4Ti.
Pretty well picked over, but the long block was intact. I may go back and grab it later but for now I just took the exhaust manifold.
I'd like to port the E6 while I'm getting the funds together to redo the whole exhaust----manifold to tail pipes.
So....where do I start with the porting process? What type of grinding stones will cut best? Should I use a gasket to match the ports? How do I clean up inside the log?
I also grabbed the elbow as long as I had it off, worth the time to port this as well?

Just as a side note, when I tried to loosen the bolts holding the manifold to the turbo...every one of the four bolts snapped off inthe the turbo. When I finally got them separated I noticed that the turbo housing was cracked where the manifold bolts to it. Is this a concern on our turbos as well? And, finally.....how do I keep from breaking the bolts on my turbo when it's time to put my new exhaust on?


Sorry for all the questions, but any advice is greatly appreciated.
Russ

[svobud]

Re: E6 manifold

Originally posted by russde
Just as a side note, when I tried to loosen the bolts holding the manifold to the turbo...every one of the four bolts snapped off inthe the turbo. When I finally got them separated I noticed that the turbo housing was cracked where the manifold bolts to it. Is this a concern on our turbos as well? And, finally.....how do I keep from breaking the bolts on my turbo when it's time to put my new exhaust on?

Pretty common - due to the years of use and heat from the turbo. You'll need to use penetrating oil (WB-40) ....let it set ...then spray it again (and let it set some more). It's time consuming - but it does prevent the "ughghhh...." *snap* factor.

[gbeaird]

You will want to get a high-speed, adjustable die-grinder. I use a Sears unit. It is about 15" long and 3" in diameter. It has served me well. A Dremmel, IMHO, is too light-duty.

You will also want to get a set of ferrous and non-ferrous cutting burrs. I _believe_ I got mine from Summit, or Jeg's catalogs, in the head/valvetrain section. You can probably get away with one set of non-ferrous (for working the aluminum intake) but get two sets of the ferrous ones, just in case.

Turbos are a bit different than NA motors in that they are blowing air through the induction/exhaust system, and at higher rates, rather then sucking the air through the induction system. Be very conservative in your porting. Use a gasket to port match the exhaust manifold, but don't use it to mount the manifold after you are done. Blend all your cutting back as far into the manifold as you can. Don't cut on the head unless you have it off the car and disassembled, ready to go to the machine shop.

Don't forget to finish up the the exhaust job with a nice polishing job. I used an old drill bit with decreasing grit wet-or-dry sand paper taped to it backwards. You want a smooth finish, but it does not need to be mirror smooth.

Don't forget, I mean DON'T FORGET to use hearing and eye protection. There is NOTHING worse than getting a metal filing in your eye. Ask me how I know. I was even using eye protection. Use the goggle type, and not the glasses type. Before you take the goggles off, go out, bend over, and shake your hair out. I think that is how I got the splinters, it was caught in my hair and dropped in after removing the goggles.

Don't forget a breathing mask, too.

Gene Beaird
86 2R SVO
Pearland, Texas

[frankiesaysrelax]

hmmm, I'm trying learn more about SVO mustangs. This E6 manifold that you speak of, did this come as OEM on the 86 SVO? What other cars did it come on, Merkurs and Turbocoupes? What years? Thanks.

[SVOeric]

This one has been covered before ---

There is no rhyme or reason -- some 86's did have the E6, other had the E3

there doesn't seem to be a date that they just swapped over -- seems like they just started working them into the line.

[frankiesaysrelax]

Thanks Eric, sounds like typical ford for ya. I am new to the forum and I am just learning about SVO cars. I really want one (and a place to keep it LOL). I made the major mistake about trying to ask about putting SVO wheels on a non SVO mustang and SVOBUD got really offended. Sorry if I ask about things that have been covered before. I always try to search and find answers before posting. There is a wealth of great info on this site. It has kept me busy reading.