Exhaust manifold port openings do not match head ports

[KEYSJUNK]

I have been experiencing exhaust manifold gaskets burning out, which creat exhaust leaks and noise.  I have had the exhaust manifolds resurfaced several different time. I have owned this motor home for around 10 years.  The unit is a 21 ft. Dodge, 440 engine, 1977.  I just recently removed the manifolds again and noticed that the left exhaust manifold has a crack in it.  My last attempt to resolve the problem was to use Felpro gaskets w/heat shields. (lasted around 350 miles)   :cry:  I hate to change to headers. Already have converted to duel exhaust.  Looking for HELP :!:

[Rodney]

go with a set of Doug Thorley headers and be done with your exhaust woes.     Really I have a set on my 440 and was one of the best improvemnents I have done to my 440. 440's need to breath and a cast manifold just don't... headers are a good thing if you start with a quality set and follow a few precautions more power and increase mpg.
Rodney

[bigray]

Will mufflers make that big of a difference. I have some cheapos from Autozone. I think they are call defenders. What are the best kind?

[Rodney]

Will mufflers make that big of a difference. I have some cheapos from Autozone. I think they are call defenders. What are the best kind?

I would guess any muffler will do the job but for a motor home I would suggest one designed for a motor home they are made of much heavier steel so the won't blow the seams out under compression the ones on my home large and have welded seams like a flowmaster muffler. I had a set of cheeper mufflers on my GTX with the 440... they lasted about 6 months and turned themselfs inside out :shock: and they also sounded awfull from the day I had them installed. pay a little more now and you won't have to do it twice. I have to keep reminding myself of that. :oops:
Rodney

[bigray]

The mufflers that came on my Clipper (they probably had been on there for ages) blew and I swore my engine was about to go. It started out subtle and grew more intense. Never was so happy to hear a noise get louder. Louder it got the more I realized it was the muffler.

They made the flapping sound during a Thanksgiven trip last year. That, my friend, you don't never want to hear!

[KEYSJUNK]

Does anyone have the part numbers for the Thorley headers for the 440 engine in a 1977 Clipper and the approximate cost of the headers.  Also I believe that one of the other post indicated that JC Whitney had headers for this application. :?

[Rodney]

Does anyone have the part numbers for the Thorley headers for the 440 engine in a 1977 Clipper and the approximate cost of the headers.  Also I believe that one of the other post indicated that JC Whitney had headers for this application. :?

http://www.rocky-road.com/thorley.html

I googled this link for the headers but don't think it is there home page?

I think you can order them from Summit
From the invoice when I got my headers in 02 I paid 236.$ plus shipping charges.
part # for 1974 to 1980   THY-109Y
thorley {Jardine performance Products} phone is 909 371 1744

I didn't have them ceramic coated as the do come plated. { you get what you pay for} :lol:
What ever you do DON'T buy a cheep set of headers for your motorhome.
This is why people will cuss and hate headers because of poor craftsmanship resulting in poor fit and quality. Thorley is the ONLY header I would put on my clipper. You will be pleased with them.
Rodney
http://www.dougthorleyheaders.com/
heres the thorley link

[Horst]

I'll chime in regarding FlowMasters - I love mine - and I'm glad I bought the "quietest" version for my 360 - my Clipper has that healthy, throaty, deep barrel  Mopar sound - beautiful!- the sound Chevy 350 and 400s  can only dream about.....right BigRay? - heh heh...........

[bigray]

No comment!

[Andy Illes]

Horst.........

Yeah.... having a Chevy's a handicap that way.  BigRay has his own way to to get "that healthy, throaty, deep barrel Mopar sound"..... just loads up on bean burritos the night before his trips....  heeeeeeeeeeeee

"New" MOPAR manifolds are still available, but PRICEY!!!  As are headers, though I sure agree that's the ultimate way to go.   If you wanna keep your stock manifolds and have a crack, any decent welder can run some stainless rod for a good-as-new fix.   Suggestion... drill small (stopper) holes at the very ends of each crack... 1/8" is fine... then weld.  Be SURE to preheat the manifolds before welding, or you'll just make 'em worse.  They'll probably warp some from the welding, so resurfacing ($20 ea) is a good idea afterwards.

Despite resurfacing mine too (thank God, no cracks) I kept having leak after leak too and would hear that lovely noise almost soon's I got it back together.... sigh.   Last time, I smeared a good, thick bead of boiler cement (Home Depot) on both sides of the gaskets, LOOSELY tightened the manifolds just enough for the cement to make contact... ran the engine 'till the manifolds got barely hot, to start setting the cement.... then cranked 'em down.  So far, so good... 1,600 mi later.

[HarryClipper]

My '77 Clipper has a 440.  The mufflers on it when I got it were "old school" 36" dual glass packs (with NOT much glass still packed I might add) and rusted and cracking exhaust and tail pipes.  

I have mentioned before that I was a "performance" part salesman back in the day of the Clipper's being "new", and did a lot of "performance" upgrade parts sales (intake manifolds, headers, mufflers, etc.)then on RV's of many sizes.

In the "90's"...Flowmaster was the "bomb" (that is slightly "old school" verbage now) and everyone was putting them on!

Now in the new milenium... most of the folks that installed Flowmaster's are...DEAF!!! :shock:   WHAT you say???  I can't (can't) hear you! :shock:

The proof of that is the fact that Flowmaster has "re-engineered" the product line to include "quieter" versions of their muffler design.

EDELBROCK has come out with a "new" spin on the Flowmaster design, and it rates taking a look at.  And for those of you who have never met Vic Edelbrock or dealt with his products...he builds nothing but quality products...PERIOD!!!  

The muffler is called "SDT" (Sound Deadening Technology) and the design review can be viewed at their website: www.edelbrock.com

My "Clip's" getting those after the Doug Thorley Ceramic Coated headers are installed.  I have the headers as I have said in earlier posting, but have been on the road with work for some time and not had the spare time to install yet.

BUT... I DO NOT use or recommend Flowmaster at all anymore.  They have become complacent and arrogaunt and therefore have been "surpassed".  

Seems to be a similiar fate of many American Companies today that care more about their bottom lines than building a good product that people WILL pay for, even more if the "quality" is there!!!

That's my story and I am sticking to it!

HarryClipper

"It is only by doing things others have not that one can advance."
-   General George S. Patton, Jr

[Rodney]

Thanks Harry I am going with the Edelbrocks when  I need to repalce the mufflers and you should really like the fit of the Thorleys Have  been enjoying mine for a year now!!

rodney