Dear Randy There so many great you tube channels that I had to decision on which ones to watch, or no work was going to happened in the shed. I have selected your channel as one of them( a senior moment) so in doing that like to start from beginning and watch all the videos ( another bad decision ) 6 months later i have caught up. I love the attention to detail when you finish of all your projects. My knowledge has expanded immensely thank you for the sharing of this information and experience. Christopher

@RRINTHESHOP

4 жыл бұрын

Well thank you Christopher for watching. That was a lot of videos.

Congratulations for winning this weeks clamping challenge....enjoyed that was some serious warpage.

@RRINTHESHOP

4 жыл бұрын

Thank you, I never win anything. Thanks Dean.

Probably too late now but drill your stud holes in that manifold out at least an extra 1/32". Most of the time stud breakage is from the expansion and contraction of the manifold bending and shearing them off.

@RRINTHESHOP

4 жыл бұрын

Yep to late, I checked that when I put it back on and it was quite loose, so I did not drill them out. Thanks for mentioning that Brian.

@swanvalleymachineshop

4 жыл бұрын

That's what Cat do as well as slot them .

@BBDos

3 жыл бұрын

Are you saying to widen the diameter of manifold bolt holes by 1/32?

@bcbloc02

3 жыл бұрын

@@BBDos Yes going up in size on the bolt holes adds safety to breaking studs.

Excellent fix, Randy! That was quite the set up!

@RRINTHESHOP

4 жыл бұрын

Thank you Reid. It worked well.

Nice work as usual Randy, thanks for the video!

@RRINTHESHOP

4 жыл бұрын

Thank you Jim.

Good job Randy. I did my manifolds about a year ago on my F150 5.4. They also were breaking studs, about 4 of them.

@RRINTHESHOP

4 жыл бұрын

Thank you Terry. I probably should of did both sides, maybe this summer.

Shaper😁. Thanks for the videos Randy

@RRINTHESHOP

4 жыл бұрын

Yeah Yeah Yeah. No room. Thanks Steve.

@SteveSummers

4 жыл бұрын

@@RRINTHESHOP LOL👍

@CraigLYoung

4 жыл бұрын

Steve is just bragging, like how he removes mill scale.

@mumblbeebee6546

4 жыл бұрын

You ventured where I did not dare go, Steve :) Seriously though, Randy: I love seeing all of the folks I watch here find good solutions whatever their shop capacity - that makes it interesting. I'd let you fix my manifold anytime! :)

Thanks Randy. I believe some companies shake out the castings before they cool enough and then they do not normalize the castings. After machining and in use, the manifold is heated and releases the tension in the casting. That in turn allows the casting to warp throwing the machining out of plane.

@RRINTHESHOP

4 жыл бұрын

Yep for sure Don. I have had problems with this manifold since the truck was new, so we will see. Thanks Don.

@donmittlestaedt1117

4 жыл бұрын

@@RRINTHESHOP i worked as Quality manager for I.H. years ago & worked with foundries. Later I owned an auto repair. Saw the same problem on hundreds of vehicles. Certain makes/models had habitual problems. You just resolved your case.

@tedsykora1858

4 жыл бұрын

Kind of irritating to have a defect from the factory

Randy, Glad you got your voice back :) Great video

@RRINTHESHOP

4 жыл бұрын

Oh yes good now. Thanks Gary.

Thanks for showing your setup. I want to do this on my MG manifold but I was stuck on the idea of using a fly cutter and doing it in one pass.

@RRINTHESHOP

3 жыл бұрын

Fly cutter would work, just watch for vibration chatter. With end mill a lot less chance of that. Thanks Allen.

Great repair. That’s one of those jobs where the setup takes about 10x longer than the actual machining.

@RRINTHESHOP

4 жыл бұрын

That is for sure. Thanks Steven.

Another job done Randy Richard right. Thanks for the video.

@RRINTHESHOP

4 жыл бұрын

Well pretty right. Thanks Harold.

Thanks for the detailed video Randy. My 2019 5.7 Ram undoubtedly has this manifold issue and the dealership conveniently couldnt find it during my bumper to bumper. Still covered under engine and trans warranty, but from what Ive read their fix is a new manifold or new bolts that will probably just warp or snap as soon as my warranty ends. Only 21k miles and been an issue since new. Can't trust em....

@RRINTHESHOP

Жыл бұрын

This repair has been fine since the fix. Thanks.

That was neat. I really enjoy complex fixturing problems. I am going to need to get or make a set of the fireball tool shim sets.

@RRINTHESHOP

4 жыл бұрын

The Fireball set of block well worth it. Thanks.

Really like the two camera views. Nice editing

@RRINTHESHOP

4 жыл бұрын

Thanks Steve.

I have a turbo flange that’s warped and is in need of this machining. Very slick

@RRINTHESHOP

3 жыл бұрын

Thank you, worked out great.

That's a heck of a challenge for setting up - time consuming for sure.! The 30 thou discrepancy on center ones is pretty severe. Great result :)

@RRINTHESHOP

4 жыл бұрын

Thanks Chris. This was a tough setup.

Nice setup. I've done a few Model A Ford manifolds the same way. 1-1/2 to 2 hours of setup time, 5 or 10 minutes of cutting time.

@RRINTHESHOP

4 жыл бұрын

Yep took a little bit to get setup. Always is . Thanks Joe.

Great stuff Randy! When we were young a small exhaust leak made the car sound faster but when we get older exhaust leaks are embarrassing... =D

@RRINTHESHOP

4 жыл бұрын

Fixed now. Thanks Scout.

@gormenfreeman499

Жыл бұрын

It also stinks when it comes in the air conditioner.

Thanks for the video Randy.

@RRINTHESHOP

4 жыл бұрын

Thank you Colin.

Always nice when you can do it yourself. Other people should have to buy a new one and have the same problems after some time.

@RRINTHESHOP

4 жыл бұрын

For sure Michel. Worked out great. Thanks.

I resurfaced mine with a angle grinder with a sanding flap, ruler and feel gauges.

Nicely done Randy, I used to work at a Dodge dealer and replaced countless exhaust studs. The thing is that under warranty the corporation will not cover manifold replacement so we were instructed to just reinstall the manifolds. A new manifold would warp again in a couple years as the heat-cool cycle relieved the casting stresses. I didn't have machine tools when I did the right side manifold on my '03 so used a belt sander with heavy grit paper to flatten it. Never had a problem with it since, you did a nicer job on yours so you should be good from now on.

@RRINTHESHOP

4 жыл бұрын

Yep bad policy. Fixed now and I know it is right. Thanks Everett.

@pierresgarage2687

4 жыл бұрын

Not sure how or if any car manufacturer does it, but the castings should be stress relieved before machining, if not done properly problems are most likely to show up sooner or later. Had 2 Dodge products in my life, more than enough to know to stay away from it......!!!! It's like they make, let's say, 60% of the vehicle great and solid and 40% total crap... That 40% or so is hell as long as you own the vehicle...

Beautiful work!

@RRINTHESHOP

3 жыл бұрын

Thank you! Cheers!

First on a Saturday Wow! Great job on the manifold Randy.

@RRINTHESHOP

4 жыл бұрын

Works great. Thanks AWDJR.

enjoyed....interesting to see the clamp setup and milling

@RRINTHESHOP

4 жыл бұрын

Thanks Chuck. Lots of blocks and clamps.

Good afternoon Randy! You need to try "Cross Rifle Coffee" if you ever get a chance, good stuff. Watching this after Mr, Pete, I was thinking you should make yourself some of his Peteblocks, makes setup a lot easier.

@RRINTHESHOP

4 жыл бұрын

I have tried it. Been drinking Pete's, goes good with our water. I have made a some Peteblocks a while ago. Thanks Craig.

That's a common problem. Another problem they have is a lot of people take the metal gaskets out and put aftermarket ones in.

@RRINTHESHOP

4 жыл бұрын

I used the metal fel pro gaskets, high quality. Thanks Ken.

Nice job Randy! Steve

@RRINTHESHOP

4 жыл бұрын

Thanks Steve, It is working great.

Now it's time to crawl around to put it back on! That was a lot of setup blocks.

@RRINTHESHOP

4 жыл бұрын

Done, Yep the Fireball blocks are great. Thanks Greg.

Nice job! 👍🏻

@RRINTHESHOP

4 жыл бұрын

Thanks MC. Working well.

Sorry about the fish story jokes. High spot checks are always a good idea to prevent those big OOPS moments. Hope you have no more problems with the studs! Great music by the way.

@RRINTHESHOP

4 жыл бұрын

Thanks Vernon.

Looking good!

@RRINTHESHOP

4 жыл бұрын

Thank you Yuchol.

Nice job. I hate working on cars& trucks !

@RRINTHESHOP

4 жыл бұрын

Thanks Mike, So do I.

Looks like that cleaned up nicely. Sounds like it was warped right from the beginning? You would think the tolerances on these kind of parts were tighter than that from the factory... Glad you got things sorted out! Hope all is well. - Tom Z

@RRINTHESHOP

4 жыл бұрын

Thanks Tom. Yep had problems with this in the first 2 months of buying the truck. Fixed now.

Dear Randy America has lost three air firer fighters today my condolences to the American people and personally to you and your family. I know you have personal high regard for these people. Christopher

@RRINTHESHOP

4 жыл бұрын

Yes, a bad accident. Thank you Christopher.

Nice job👍👍👍👍

@RRINTHESHOP

4 жыл бұрын

Thanks Gib.

the other thing i would have checked for Randy, is how the thing acts when heated up.. hit it with the acetylene and see if it teeter totters any more or less on the table

@RRINTHESHOP

4 жыл бұрын

Yeah but I am not going to machine it hot. I went with it, Working well. Thanks Mike.

The sound effects made me look up and pay attention. Like watching an action movie. Lol

@RRINTHESHOP

4 жыл бұрын

Thanks George.

Great job on the manifold Randy. I've done quite a few of them over the years and had to do the same thing on ones that are out .040" plus but on many that aren't off that much I merely breath across the belt sander with them to true everything up. I've had to do it with new "green" manifolds even. I generally try to get them where a .004" feeler gauge won't slip under on my surface plate and haven't had any further issues so if you're only off a couple thou you should be just fine. Also they are already "seasoned" manifolds so you shouldn't have to do them again. Mike

@RRINTHESHOP

4 жыл бұрын

This a bit far out to sand off. Thanks Zmotorsports.

Here we see Mr Randy Richards Speed Milling World Champion in action.

@RRINTHESHOP

4 жыл бұрын

Have to get done. Thanks Malcolm.

Now that the stresses are probably well released from that part, what you just did will give you a very stable manifold, better than a new one that wasn't properly stressed released... Nice stable and solid setup.... A few thou difference will be well taken care by the gasket... Hope the other side is gonna be alright. I've seen Everett's comment below, no wonder it happened again and again, sounds like Dodge don't make enough money from the showroom, so they purposely make it so you end in the repair shop to get their hands on the rest of the money... Got caught in that circle with 2 vehicles, now I stay away from Dodge products...

@RRINTHESHOP

4 жыл бұрын

Thank Pierre. Working well, the Right side I have never had a problem so far.

Nice job, isn't it nice to have the equipment and knowledge to do your own repairs...

@RRINTHESHOP

4 жыл бұрын

Sure is. Thanks RC.

I need to do the same thing to the driver's side header in the jeep. It has leaked since day one. Added an extra gasket and torqued the bolts after a couple of heat cycles but it still leaks.

@RRINTHESHOP

4 жыл бұрын

Geterdone in that new shop. Thanks Tom.

I have to replace the gasket on my 2010 GMC 6L. Not looking forward to doing it. Nice setup and result. Must be white cast iron, do you think. Grey would have been easy to do with HSS. Take care Randy

@RRINTHESHOP

4 жыл бұрын

Just the surface was hard, The endmill made it like butter. Thanks Randy

Looks great. I’m working on a similar setup with the driver side and was curious when you clamped it down what were your tolerances for getting it parallel to the table?

@RRINTHESHOP

23 күн бұрын

Since it was not flat/warpped, I just had to average out the the reading in x and y. Get it as flat as you can. This worked out so to remove as little as possible. I have since done the other side also. Both are holding up and I have not had to touch them since. Thanks for stopping in.

Nice job Randy, I’m sure the manifold gasket will take a few thou? Kindest regards. Joe.

@RRINTHESHOP

4 жыл бұрын

Thanks Joe. Working well so far.

Excellent video! What would you say a machine shop might charge for this, per manifold? I like this much better than buying new manifolds or headers. Also, how important would you say expanding the bolt holes are?

@RRINTHESHOP

4 жыл бұрын

Well if they were setup to do this I would say a hour of labor. Take note when removing and if there is rubbing on the stud I would enlarge holes a s necessary.

@whiplashmachine

Жыл бұрын

@@RRINTHESHOP I do this fairly regularly and an hour is my charge. I have a horizontal mill, so my setups on these odd jobs are quite easier than on our vertical mills. Nice work👍

Nice job. Just curious why you were taking such thin cuts? I'm sure the mill and cutter could have single passed the 3 others after you established the reference height, so you must have had a reason.

@RRINTHESHOP

4 жыл бұрын

Just being careful, the last thing I would of needed for something to go south. Thanks Barry.

Nice job Randy, how much were you taking off on each pass and what rpm were you using? Thanks again, hope to see you at the bash. Your friend Jim, (the guy with the clausing 5914), JB San Diego.

@RRINTHESHOP

4 жыл бұрын

1" Carbide endmill, 1600 RPM, about 0.030 roughing, 0.010 finish. Thanks Jim.

I've done this job several times. My mill table does not appear to be any larger than yours, (mine's probably smaller.) I've always made one setup and cut all ports at the same time with a 3" face mill. That way they have to be in perfect alignment and it doesn't take much time. Does your table not have enough travel?

@RRINTHESHOP

4 жыл бұрын

Thank you Ken. I had enough travel. This was a faster setup for me and what I had.

Nice job Randy - What no road trip to bring it down to get it ground??

@RRINTHESHOP

4 жыл бұрын

Thank you Eric, That would of been a bit over the top.

How is it possible you did not crashed into clamps as I always do? :-) Nice setup.

@RRINTHESHOP

4 жыл бұрын

Careful Careful Careful. Thanks Milan.

Randy, It’s been three years, any broken studs since the milling job? I have read that warped brake rotors, exhaust manifolds etc. are less likely to warp again once re-machined flat, would your experience support that notion or not? Thank you

@RRINTHESHOP

Жыл бұрын

Still working great, I also did the other side manifold last year. Yes after many heat and cool cycles more stress is relieved and I have found a remachine like this makes them last a lot longer.

looks like i'm not the only one that uses fireball tool spacers in the machine shop.

@RRINTHESHOP

4 жыл бұрын

Yes Daniel, i use them all the time, Great Block. I need another set. Thanks Daniel.

They make cast iron manifolds so thin nowadays to try to save weight and dollars! I’m surprised that doesn’t happen more often.

@RRINTHESHOP

4 жыл бұрын

I am sure this does happen a lot. Thanks John.

I can explain why your dealership couldn’t solve this problem for you. A warped or improperly machined piece of cast iron doesn’t throw a fault code and if they don’t get a code when they connect the diagnostic, you don’t have a problem. In my recent experience with dealership shops, I don’t think they could diagnose a flat tire without a code.

@RRINTHESHOP

4 жыл бұрын

Figures. Thanks Joe.

It seems like the engine might be warped in the same way the manifolds are and this could end up causing more of a gap? Or would this never be the case

@RRINTHESHOP

3 ай бұрын

Head warpage is very rare. I have had no problems since I have done this, I did this to both sides. Thanks.

Hi, did the machining process work? Did it fix the leak in the long term? Best from Germany!

@RRINTHESHOP

3 жыл бұрын

Yes, no problems still working great. Thank you.

@holzwurmflo

3 жыл бұрын

@@RRINTHESHOP thank you for your answer, we will try this on my brother’s truck. Best Florian

I don't know for sure but at the beginning I could swear you have the cutting tool installed in the fly cutter the wrong way.

@RRINTHESHOP

4 жыл бұрын

No, the surface hardness was to much the get cut started. The end mill was no problem, I could cut deep enough below the hardness. Thanks Jason.

Cheaper to buy new for the avg guy?

@RRINTHESHOP

4 жыл бұрын

Sometimes, Thanks.

So much for "Ram Tough".

@RRINTHESHOP

4 жыл бұрын

Well it did last quite awhile and this is my 3rd dodge truck. They have been great. Thanks Gary.

@rustycowll5735

4 жыл бұрын

I applaud your restraint. I see so many dumbass trolls on these video comments.

@garybrenner6236

4 жыл бұрын

Thank you Randy, for taking it as the joking comment that it was, I also own a Dodge.

Would be easier to put it on a table belt sander.

I’ve heard said that a warped exhaust manifold is a sure sign of a warped mind. Well, maybe I just made that up, but anyway...

@RRINTHESHOP

4 жыл бұрын

Well I am not sure who or what was warped but this fixed the problem. Thanks Greg.

To bad that they don't stabilize there parts before they mill them. You really had to break out all the set up tricks to hold this one lol .

@RRINTHESHOP

4 жыл бұрын

Yep wish they would. lots of work on the setup.

@OldIronShops

4 жыл бұрын

@@RRINTHESHOP cheaper to warranty it multiple times in the Long haul I suppose.

Is that a dodge?

@RRINTHESHOP

3 жыл бұрын

Yes, 2009 Ram.

@superchile9640

3 жыл бұрын

Randy Richard In The Shop my 2012, which has 45,000 miles on it is now at Dodge because of this and the o2 sensor on that same pass side and now won’t start

Buy some new ones.

@RRINTHESHOP

Жыл бұрын

Why, they are no better.

i don't think we need to see the entire milling process for 5 minutes, which is pretty straightforward.

@raymcdonald731

Жыл бұрын

Then don't watch!!

What's with the music bro