BRINGING IT ALL TOGETHER.... A's, G's & E's


Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

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jdlaugh

Number of posts : 216
Location : Tulsa, OK
Registration date : 2013-03-18

Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by jdlaugh on Sat Aug 19, 2017 2:33 pm

Ive long wanted to adapt the modern, higher flowing EFI manifolds for my 240 engine, but the front manifold sticks out too far and I didnt want to modify the doghouse or floor. Fellow Econoliner Terrance Kritzberg kindly mentioned in a recent Facebook post that two rear manifolds might work with modification. And, he was right.

I had to do a little cutting and brazed on a flange, but it was a fairly simple project and the fit is good. Ive only bolted on the front so far, but the rear manifold should be even easier. There is plenty of clearance.

The downpipe from the front manifold could go over the top of the motor mount and cross member with a really sharp bend, or drop straight down and then 90 under the cross member.

I think this setup will flow dramatically better than the old log manifold, and will be a great complement to my custom TBI setup. Cost for the two rear manifolds was just over $50 from my local salvage.

Here are some pics. I had to make 3 cuts, marked in red, and grind down one tab to the right height for the mounting bolts, then finally braze on the flange.

Looks clean with plenty of room to clear the doghouse. I think this will be easy to wrap with header wrap or a heat shield and should dramatically reduce heat in the doghouse.



Required cuts marked in red. Note the upper left must leave a tab for the mounting bolt similar to the one in the center.



For some reason one of the bolts on the back manifold is in the center instead of on the edge, so the flange must be trimmed and profiled.



The cutoff tab needed to be profiled to match the one in the center.



I had to remove about an 1/8th of material with a dremel.



The final step was brazing on a flange. I used standard bronze flux-coated rod with an oxy/acetylene torch. This is my only area of concern -- will the braze job hold. It's not carrying a load or under much stress, but some have warned the extreme heat of the manifold may weaken the brass braze over time and lead to failure. If it fails, I'll clean up the area and try stick welding.



Last edited by jdlaugh on Sun Aug 20, 2017 1:14 pm; edited 2 times in total
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Zonk 1/75

Number of posts : 56
Location : Yachats Oregon
Registration date : 2016-06-24

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by Zonk 1/75 on Sun Aug 20, 2017 10:48 am

nice....
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Wolfster

Number of posts : 91
Location : Omaha, Ne
Registration date : 2016-08-27

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by Wolfster on Sun Aug 20, 2017 3:19 pm

JD, you do some damn nice technical posts! Thanks for sharing your efforts.
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jdlaugh

Number of posts : 216
Location : Tulsa, OK
Registration date : 2013-03-18

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by jdlaugh on Mon Aug 21, 2017 5:58 am

Thanks. I hope somebody finds the info useful.
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Seth G
Vintage-Vans Listings Manager
Vintage-Vans Listings Manager

Number of posts : 1646
Location : Anacortes, WA
Age : 44
Registration date : 2013-04-24

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by Seth G on Tue Aug 29, 2017 5:32 pm

If I had a 240/300 truck I'd be all over this.
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jdlaugh

Number of posts : 216
Location : Tulsa, OK
Registration date : 2013-03-18

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by jdlaugh on Sat Sep 16, 2017 3:09 pm

To make the rear manifold work, I had to cut off the two ears at the top, similar to what I did with the front manifold. Once I had both manifolds modified and painted, I broke out the welder and tacked together the front half of the exhaust system. I bought two mandrel 90s to help with routing, but had to cut and tack a 25 degree angle on each pipe to get the correct arc. In the end, I ended up with an arch of 115 degrees (90 plus 25) on each piece of 2" aluminized exhaust tubing. Good clearance from the floors and the starter. First time I've tried something like this, but I'm happy with how it's going so far!









Last edited by jdlaugh on Mon Sep 18, 2017 9:42 am; edited 2 times in total
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Seth G
Vintage-Vans Listings Manager
Vintage-Vans Listings Manager

Number of posts : 1646
Location : Anacortes, WA
Age : 44
Registration date : 2013-04-24

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by Seth G on Sun Sep 17, 2017 8:01 am

That's looking good JD
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jdlaugh

Number of posts : 216
Location : Tulsa, OK
Registration date : 2013-03-18

Re: Installing two REAR EFI manifolds on the 240, and staying inside the doghouse

Post by jdlaugh on Mon Sep 18, 2017 9:40 am

Finished downpipe ready to install. I used VHT Flame Proof header paint to dress it up and hopefully slow corrosion.


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