Hey, I'm gonna start a full rebuild on my 617.952 in a month or 2 for my 84 fj60, and I've been making custom parts in solidworks. I'm curious if anyone has a pattern for the exhaust manifold bolts and holes... I would like to make some headers for it, but I don't want to open a can of worms taking off the manifold to get a pattern down as It's being used as a daily right now. When I start I will post a build thread, it'll be fabulous!
Newbie to the forum, not sure if this is the right place to put this, oh well

The turbo bolts to the factory exhaust manifold. Do you plan to re-plumb all of that? Seems the factory exhaust is a nice design, w/ a very large pipe (3"D?) for a 5 cyl, compared to what you see on even a V-8 gas car. People say turbo diesels need that breathing. I would think a 4WD would care more about low-end torque than max HP anyway, which is why they like diesels. Anyway, everyone here would appreciate photos of anything custom, even if we can't help you.

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

Save yourself the effort and just buy these - FS-617 Blank Exhaust Flanges

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Current Stable

• 380SL (diesel)
• Corvette C5
• Manx
• Baja Bug
• F350 Powerstroke
• Auburn Boattail Speedster replica

Those flanges look pretty, I could save a ton of time with those... How I didn't find those while searching is way over my head...

I plan on getting a different turbo to keep up with a 7mm ip I'm having made, also the engine is gonna be all pretty painted and some powder coated parts etc so headers will be necessary, can't blame me for that! Will be a few months till I start a project but I PROMISE I will make a build thread.

FWIW "headers" is the wrong term for a turbo manifold, AFAIK

For inspiration here's plenty of Euro guys with custom posh manifolds on their 617s getting power most on this forum would not believe.

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1978 300D, 373,000km 617.912, 711.113 5 speed, 7.5mm superpump, HX30W turbo...many, many years in the making....
1977 280> 300D - 500,000km+ (to be sold...)
1984 240TD>300TD 121,000 miles, *gone*
1977 250 parts car
1988 Toyota Corona 2.0D *gone*
1975 FJ45>HJ45
1981 200>240D (to be sold...)
1999 Hyundai Lantra 1.6 *gone*
1980s Lansing Bagnall FOER 5.2 Forklift (the Mk2 engine hoist)
2001 Holden Rodeo 4JB1T 2WD

Tube headers may not be All That on a turbo engine. I'm running a Dieselmeken SuperPump and am about to install a big honking turbo on the stock manifold.

The deal is - tube headers are VERY crack-prone in a turbo application partly due to having to support the turbo and partly due to expansion and contraction caused by heat. You can build brackets to support the turbo mass but then the brackets have to move with the expansion, too - not easy to do. I know a guy who can make excellent and durable turbo headers (he's made most of the Ford prototype headers for their turbo experiments) and he says "use cast manifolds if you can". My turbo guy made a hybrid turbo for me so it can bolt to the factory manifold but run a much bigger compressor.

Check out my engine - it's pretty good looking. I'd suggest that you get a nice stock manifold and have to ceramic coated if you think it'll even show - you can barely even see mine in the S-10.

Dan