Repairing the rust on an exhaust manifold
June 2026
- Problem
- On a three-cylinder city car, the flange where the exhaust manifold bolts to the cylinder head had rusted through. Exhaust was leaking at the engine and the flange couldn't be repaired as it was.
- Solution
- I took the front end off, pulled the manifold and catalytic converter, drew a new flange and cut it out on the waterjet. The new flange was then fitted to the original pipework.
- Result
- Sealed and ready to go back in. The manifold could be reused instead of replaced.























