Other ( non boosted Renault ) Tubular manifold for C2J engine

[ReidarUF]

I have a C2J engine from a Super 5 TS I plan to put in my -64 R8. The ingine in stock form is a huge improovement but I plan to convert it to EFI and ITBs. I have found two nice little pairs of bodies from two Kawasaki Vulcan 900 that match the inlet ports perfectly. I will cast the inlets in alumunium.

Anyway I will also build a tubular manifold for it using two Opel/Vauxhall XE manifolds for materials.The C2J share the same manifold gasket as the C1J/Gt turbo so I thought I could buy a premade exhaust flange to save some time. But for some reason Renault have not only ditched the four bottom exhaust studs, but also the material holding them.



There is NO studs for the lower section of the exhaust flange making it rely on clamping force from the inlet. The OE inlet/exhaust is bolted together so quite rigid. But there is still clear that the two middle exhaust ports have been leaking.
The new exhaust manifold will not be bolted together with the new inlet the same way.

I think I will either have to drill 3 or 4 new stud holes in the remaining material(marked with black dots) (scary?)to get enough clamping force, or to let the two bottom inlet bolts be shared with the exhaust. In that case I think I will have to cut the flange from L-profile instead of flat iron to make it rigid enough. There is also a threaded bung in the block just under the two middle exhaust ports that might be used to improove clamping force.

what do you guys think? Have this been done before?

 

[ReidarUF]

It seems the C2J engine is quite common in Latin America in R9 and R11. I found two examples of tubular manifolds on mercadolibre(latin for ebay) and it seems like they simply let both flanges share the two bottom inlet studs. It looks kinda flimsy to me but I guess I worry to mutch.

 

[Adey]

good find, not sure on the stud location, it might be worth seeing if the c1j is any different as that has a manifold with a turbo hanging off it too.

 

[ReidarUF]

Here is a link to another manifold with bether pictures. For some reason I'm not able to either upload the picture or insert the link for it. The material in the flange look thick and I guess the pipes add rigidity as well.
Multiple Renault 9 / 11 - Con Acople Bellasilens Fabricante - $ 2.541,00

 

[Adey]

im sure there is meant to be a soft washer that takes up the slight difference in material thickness between the inlet and exhaust flanges. if they are all faced off with a decent gasket you shouldnt have issues with it leaking

 

[ReidarUF]

I think the material where the washers and nuts for the studs that is shared sits are supposed to me mashined to exact(or cliose to) same thickness. I guess an annealed copper or alloy washer would be able to take up a slight difference.

 

[niconkk]

I think the material where the washers and nuts for the studs that is shared sits are supposed to me mashined to exact(or cliose to) same thickness. I guess an annealed copper or alloy washer would be able to take up a slight difference.

i've done a L shaped washer to sit straight, but i seen a regular washer and that's it in c3l (Argentina) non turbo manifolds

 

[niconkk]

first attempt, but that washers stays up to today with copper nuts

 

[ReidarUF]

Trick washers is of course another option to get enough clamping force on both surfaces. Not pretty but it works

 

[niconkk]

 

[ReidarUF]

Actually the washers looks rather good.

I made up a drawing today to bring to the local mechanic school to have them make up two or three flanges. Where inlet and exhaust share the bolts i will leave the material till after welding.
Off cource they would prefer a cad file...

 

[Gary]

Nice Work, The throttle bodies look like a great find