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Onan CCK Manifold Restoration


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  #1  
Old 10-20-2009, 01:44:45 AM
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Default Onan CCK Manifold Restoration

First pic is of the Onan CCK intake/exhaust manifold before I attacked it! Second pic is after a few spins in the Steelabrator. What's a Steelabrator? It's a really nice tool for cleaning cast iron using millions of super small steel buckshot. Third pic shows a few thousand of them inside the carb port. Fourth pic you can see the impeller blades that spin the shot around the manifold that is mounted to the cage that rotates.

But wait! How did you get those rusted tight exhaust pipe nipples out? Well, you sure don't try and remove them cold! HEAT! Lots of it! Small propane torch ain't gonna do it! Get a real torch and heat up the area where the threads are on both the pipe and manifold a dull cherry red. Get the manifold glowing nice before hitting the pipe with the torch, it will take a few minutes. Get that sucker glowing real nice but not so you start melting it! Shut off the torch and get a nice grip on the nipple with a vise grip and see if it will turn. It should let go, keep turning it unless it gets tight. Work it back and forth until it comes out. You may have to heat it up again and repeat. Don't force it! Unless you want to have a two or three piece manifold...

Up next Mr. Milling machine...
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  #2  
Old 10-20-2009, 01:53:30 AM
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Default Re: CCK Manifold Restoration

Bottom side I milled the gasket surfaces first.
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  #3  
Old 10-20-2009, 01:59:02 AM
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Default Re: CCK Manifold Restoration

Top side next. The exhaust flanges were pitted pretty good.
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  #4  
Old 10-20-2009, 02:04:20 AM
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Default Re: CCK Manifold Restoration

But they cleaned up nice. This manifold did not have both sides drilled and tapped for flange style exhaust so I took care of that problem.
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  #5  
Old 10-20-2009, 02:09:01 AM
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Default Re: CCK Manifold Restoration

Almost done. The vacuum port was already there and plugged but I'll have to drill and tap the mounting hole for the vacuum assist booster used on some models.
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  #6  
Old 10-20-2009, 10:18:12 AM
Dave Edmonds Dave Edmonds is offline
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Default Re: CCK Manifold Restoration

Nice looking work!
My dad was in the structural steel business and had a "wheelabrator" - could blast 24" tall steel beams down to white metal in a continuous process - beam went in one side and out the other. They fabricated quite a bit of steel for NASA that required that level of cleaning (never understood quite why that level - most of it was in the structure of buildings). The steel had to be primed within a few minutes or it would start to rust.
Dave Edmonds
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Old 10-20-2009, 10:32:17 AM
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Default Re: CCK Manifold Restoration

The machine I have access to will do about a 2' long piece. Cast iron or thick steel. I spray parts down with wd40 if I don't plan on painting ASAP. That old rust will come back really fast!

TJ
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Old 11-02-2009, 12:26:10 AM
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Default Re: CCK Manifold Restoration

Found another CCK manifold to restore. This one the prior owner attempted to remove the rusted/frozen muffler flange bolts cold and busted the ear off one side. They stopped while they were behind. I used high heat on the other side and removed those bolts without causing any damage. This manifold is a perfect example of why you want to use heat instead of trying to force a frozen or rusted exhaust bolt off cold.

Welding cast iron is an art best left to those who do it well. I'm lucky that there is a really good cast iron welder local with a walk in oven he uses to weld up cast heads, manifolds etc. He'll pick this one up next week and when I get it back I'll put it on the mill and return it to where it is like new again. More pics on that part of the resto soon.

TJ
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Old 11-02-2009, 03:23:17 AM
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Default Re: CCK Manifold Restoration

Short video showing the removal of a frozen/rusted exhaust bolt on the CCK manifold via the proper "heat" method. If the bolt does not turn free as shown here the first time don't force it. Reheat and try again. Don't melt the manifold! Get it glowing cherry red hot around the whole area of the bolt. Once you put a vise grip or in this case a socket on the bolt head it will cool the head just enough to keep it from twisting off as long as you wait a few seconds before trying to remove it. Manifold hot, bolt not quite as hot is the key or you will twist the head or what's left of a stud off and really be screwed!

TJ

http://www.youtube.com/watch?v=lYSZncjnzVs
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  #10  
Old 11-30-2009, 11:31:36 PM
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Default Re: CCK Manifold Restoration

Second CCK manifold has returned from the walk in welding oven. Broken ear has been built back up and the other threaded flange mount hole was filled in since the threads were looking pretty bad. In the next few days Mr. Steelabrator for some final cleaning and then off to the milling machine.

TJ
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  #11  
Old 02-01-2010, 04:48:01 AM
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Default Re: CCK Manifold Restoration

Well it took awhile to get around to finishing up the second manifold but I had a few hours today to button it up. Turned out ok.

TJ
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Old 12-27-2011, 12:38:57 AM
lijobi lijobi is offline
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Default Re: CCK Manifold Restoration

I used Onanparts' heating method on a MCCK manifold with 2 broken bolts. It worked perfectly. Fortunately, there was enough of the stud left to grab on to. Definately need an acetylene torch to do this, though. Thanks for the tip.
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Old 05-22-2014, 10:57:08 AM
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Beautiful!
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Old 05-22-2014, 11:47:34 AM
grif grif is offline
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Default Re: Onan CCK Manifold Restoration

Walk in oven. Wow. I've done a couple of small cast items with nickle rod with the item sitting on bricks and heating with a torch, doing a "spot weld", and back with heat and peening,,, and just back and forth to fix the crack. Had good luck with the small stuff.

The thing that always bothers me, the finish after it's done. Not wanting to hide the fact that it was a repaired part,,, but that bead machine sure makes things look nice and factory new! Gotta find a small shop around here that has one.
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Originally Posted by onanparts View Post
Well it took awhile to get around to finishing up the second manifold but I had a few hours today to button it up. Turned out ok.

TJ
So how do you set the work up to get both flanges on the same plane? Just set up the undamaged one level and cut the repair to match then do a cleanup cut on both of them?
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