I have a Cummins L423D diesel engine that I am trying to slightly fix up.
It has a muffler that was hit from the top sideways (when the engine was being moved on a forklift, I suppose).
Anyway, the muffler attaches to exhaust manifold by means of a diamond shaped flange and two bolts on the far ends of that diamond. (I can make and post pictures on my webpage).
The impact made that flange non-flat, like a "saddle". The thickness of the flange is about 1/4". The deflection is about 3/32" (guesstimate).
I would like to straighten the flange somewhat. I do not have a forge but I have a piece of rail, some assorted 4140 blocks and sledgehammer (3 and 8 lbs, IIRC). I also have a decent TIG welder.
I see two choices:
1) try to straighten the flange by putting it on the rail or flat 4140 block and pounding. (cold)2) Try to weld a little filler to some areas and then grind the surface to be reasonably flat (should be fine with a gasket).
The muffler's body was also bent a little bit (where the pmuffler's pipe enters its cylindrical main body) but I already fixed that sufficiently to provide clearance for the oil fill cap.
So... any flange straightening suggestions will be gratefully received. I can provide pictures, as I said.
thank you.
i