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I decided to have my exhaust flanges
recut to better match the ports. Originally I simply had a 2" dia
hole. How important is it to match the shape of the ports, which is a
collection of radiuses, straight sides, fillets and even a sort of
non-tangential "fillet". It appears that a 1 7/8" OD tube could be
hammered to match this shape if I had it cut in the flange. A 2" OD tube
left round also looks like it would cover the port, but would leave edges
where the straight edges of the port would dump into a round pipe. These
areas are very small. My welder says that he routinely hammers exhaust
pipes into "square" shapes, that the ports usually aren't round anyways.
He can stretch the pipe to a bigger dia., although I don't think that is a great
idea, despite my using 1/16" wall 321 s/s. I realize that I don't want the
exhaust gas to collide with a smaller exhaust pipe shape, but what about a
larger size? Is it OK to spill into a slightly larger size? Am I
worrying too much about a small detail, or is this worth the time and
effort?
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