I came across a Caterham K-series exhaust manifold on Blatchat, so I thought I would fit it and put the exhaust more inside the bonnet (replacing the "over the side rail" one I used to have.

As luck would have it, I managed to get away without any pipe welding - just got a stainless bend from Jetex to join the bottom of the collector to my old side pipe. I also needed to move the can up a little bit to make sure it is level.

To cover up the hole in the side where the lamda sensor came out I made a patch piece (see thred here)/

I made an ali heat shield (cardborad template trimmed and folded by trial and error) to give some protection to the starter, etc. which are quite close. It is held on by tabs on a couple of the manifold studs and an exhaust U clamp. I also made an ali heat shield for the top hose... I will check this out and may reroute the hose over the top of the top rail if it looks like it is overheating.

Finally, I made a patch to cover up the hole in the side of the bonnet and riveted it in place. Gives it some character (that's what I say, anyway!).

Apart from a few cuts, and having to cut down the manifold studs a bit to make positioning easier, they only major problem might be if I have fcuked the lamda sensor - it touched the exposed nut of the live wire going to the starter, and there were a few sparks. Looking at the sensor, it now has some nice holes burned in the metal on the side I fitted it all up and started the engine OK, but it may be better to replace it.

(N.B. I have since rubbed down the side panel patch with scotch pad to give it a matt finish and blend in with the rest).

Cheers,

Simon
Rescued attachment 2008-04-05 Exhaust.JPG

maybe one option would have been to use louvered vent sheet to cover the hole in the bonnet, then at least it would let the hot air out. Heat shield looks good.

[Edited on 5/4/08 by Mr Whippy]

Well... I've got one vent in the side of the bonnet there already. If it gets too hot, I'll think about putting another one in