Census for possible production of Exhaust Flanges 40-60 serise

[love2fly]

Another small part?
Just recently I started working with my 40 series exhaust system were I removed all but the pipe coming from manifold for a complete exhaust replacement. As most who do this on an older rig (30 something in my case) find the bolts are rusty and the pipe/flanges/gaskets are not in there prim as they once were. This is a 1982 40 series so it has the three bolt coupler flanges for 2" pipe. All the flanges were found to be barely usable and needing replacement. That's were this census comes in.
After long searches on the web, local exhaust shops, and even to China looking for a stock flange as Toyota made I came up with nothing usable. Toyota did not sell these flanges they were part of the exhaust system - no part numbers.
Before you say " just have them made" I did just that and found that most all were just to busy to bother on a small amounts, and were well over priced.
Long story short, I find a outstanding company in the US that will make a few sets for me , this means that their C & C machine will have all the specs programed for future production for this 2" stock pipe coupler flange (not the offset bolt manifold flange). See the borrowed picture below of the flange to be made.
This coupler flange was used on various/years Land Cruiser 40-60 maybe others.
If you want to weld on your own to keep it stock this would be one way.

Question:
Would you be willing to buy a set or more of theses flanges if available and if priced reasonable ?
Post how many you would be possibly interested in. I know price drives the train but that's something the company will have to state if they produce a large amount.

This is not in my interests as I have already made the deal with the company for my parts to be made, but for you others that may also want to keep it stock and do not want to deal with local machine shops or different types of universal thin exhaust flanges with flat gaskets.

If the interest is good the shop making mine may make a large batch to be available of others.


Note: if you have a shop that made some for you to specs-and can reproduce without the set up cost - please post that information, this information is for all us Land cruiser owners.


Cheers

 

[snaggletto]

Just have them quote 10, 20, 50 pcs. You buy them and get the volume discount. Then resell yourself. You will end up making money if you do it right.

 

[tstepp920]

Can you tell a lazy man if the flange for all 2Fs are the same. Will your proposed reproduction fit a May of 80 2F

 

[Spike Strip]

I would probably get a couple pairs - But curious why the Overland Adventure Company flanges (LINK) won't work for you?

3 BOLT EXHAUST FLANGE

 

[iptman]

I would probably get a couple pairs - But curious why the Overland Adventure Company flanges (LINK) won't work for you?

3 BOLT EXHAUST FLANGE

I used @hairy_apple 's over sized 2F manifold flange in my custom exhaust and it fit perfectly. $40 less than SOR to boot.

 

[hairy_apple]

This is the other end, the side that attaches to the muffler, not the manifold. If I had access to the down pipe, I could easily make those, to order. No need for a minimum.

Anyone want to get me dimensions?

 

[Michael Hanson]

Hi, Dorman makes them. Mike

 

[65CRUISER]

I own an aerospace CNC shop in the Phoenix metro area and we are making these for @love2fly without a minimum or set up charges. We can run a larger lot if anyone needs a flange at the same time we are making the parts we have already contracted for. $10 ea. plus the ride.

 

[Splangy]

It can’t be that hard to find 3-bolt flanges for 2” pipe. NAPA and other suppliers have big catalogs full of this stuff.

 

[love2fly]

Custom exhaust is one thing but here I am saying original style replacement flange.
I am not sure what years they fit probably any year with 2" pipe, you just have to do the leg work, sorry. Mine is an 1982.

The main point to this is, it will except the stock Toyota gasket and fit some of the stock hole to hole exhaust hangars found on some of the 79s and up. That's all.

If NAPA has one you want then that's the one you use, but most all are with a flat gasket seal and thin steel.

They can be used any place on the exhaust below the manifold pipe but not the manifold, that is a different flange.
On the US 40-60 models with Cat converters they usually have them also unless it is an aftermarket CAT.

For reference only:

The Overland Adventure Company flanges (hairy_apple) look fine but just lack the 2mm recess for the Stock gasket. That would be great if you want to make some also, I do not have the dimensions and my stock flange were sent to 65CRUISER who is going to do the production of a few as he mentioned.

Hi Mike, haven't seen the Dorman one's, will take a look.

It's all about using Original Style, nothing more nothing less. Pretty simple.


Thanks guys.

 

[Splangy]

Custom exhaust is one thing but here I am saying original style replacement flange.
I am not sure what years they fit probably any year with 2" pipe, you just have to do the leg work, sorry. Mine is an 1982.

The main point to this is, it will except the stock Toyota gasket and fit some of the stock hole to hole exhaust hangars found on some of the 79s and up. That's all.

If NAPA has one you want then that's the one you use, but most all are with a flat gasket seal and thin steel.

They can be used any place on the exhaust below the manifold pipe but not the manifold, that is a different flange.
On the US 40-60 models with Cat converters they usually have them also unless it is an aftermarket CAT.

For reference only:

View attachment 1864235

The Overland Adventure Company flanges (hairy_apple) look fine but just lack the 2mm recess for the Stock gasket. That would be great if you want to make some also, I do not have the dimensions and my stock flange were sent to 65CRUISER who is going to do the production of a few as he mentioned.

Hi Mike, haven't seen the Dorman one's, will take a look.

It's all about using Original Style, nothing more nothing less. Pretty simple.


Thanks guys.

You can use the original ring gasket with the aftermarket flange. You don’t need the recess there for a good seal. I’m all for making things as original as possible, but why reinvent the wheel for a couple of subtle casting marks nobody will ever see?

 

[Dizzy]

Possibly start with Overland Adventure Company's if they are made from the appropriate HRS (hot-rolled steel), have clean, round bolt holes, and have the correct OEM profile. Then have a shop fab a jig, which is fit into the jaws of anyone's lathe, to bolt the flange to. The recess can then be counter-bored easily without having to actively find the center of the flange, and could be made to order in small batches without much fuss. CNCing this on a milling machine would be possible, but you'd be making tons of metal chips just to get the profile, and steel is a inherently a slow machining material. The Torchmate plasma cutter from Hairy Apple is the way to go.

The recessed profile is to center the gasket on the flange during assembly.

I might be able to help with a CAD illustration.

 

[Splangy]

Possibly start with Overland Adventure Company's if they are made from the appropriate HRS (hot-rolled steel), have clean, round bolt holes, and have the correct OEM profile. Then have a shop fab a jig, which is fit into the jaws of anyone's lathe, to bolt the flange to. The recess can then be counter-bored easily without having to actively find the center of the flange, and could be made to order in small batches without much fuss. CNCing this on a milling machine would be possible, but you'd be making tons of metal chips just to get the profile, and steel is a inherently a slow machining material. The Torchmate plasma cutter from Hairy Apple is the way to go.

The recessed profile is to center the gasket on the flange during assembly.

I might be able to help with a CAD illustration.

The recess doesn’t help with centering the gasket. The gasket ID should be pretty close to the OD of the male section of pipe so it doesn’t allow movement. This is a lot of work for a 2mm recess that isn’t seen and isn’t necessary for a proper seal.

Also, the Female side of the pipe at these flanges was often swaged from the factory to allow the male side to slip into. Do you guys plan on recreating that same swaged increase in pipe diameter? That’s something you’d actually see if you’re so worried about a perfect OEM match. Some OEM versions were simply welded with a short pup piece of larger diameter pipe. Which version do you have?

I applaud it anytime somebody takes a project like this on, but in this case it just seems completely unnecessary. Seems like one of those times where a lot of people say they’d be interested in one but aren’t likely to follow through when they realize they can likely just buy one at NAPA for likely 1/4 of the price.

 

[cruiserboy14]

I’d be interested if it fit my 77. Ol looking at a replacement exhaust myself.

 

[hairy_apple]

I have no idea what the down pipe side looks like, but on the manifold, the gasket recess is on the manifold side... so there is no need for one in the flange.

 

[Living in the Past]

I’d be interested if it fit my 77. Ol looking at a replacement exhaust myself.

Your muffler/tailpipe is NLA. Original would be four bolt flange. The 1/79+ muffler/tailpipe was available last time I checked. One of these flanges would mate to it. Would need to figure out the hanger at the end of the tailpipe but doable.

 

[Living in the Past]

One man's junk is another man's treasure. These were all removed from a cruiser getting a V8 and were headed to the recycler.

 

[love2fly]

Living in the past, your the man, if you can find them, recycle them.
I looked for the cats on and off for a while, most people just toss them. Looks to be in good shape, Nice save.

 

[Living in the Past]

Living in the past, your the man, if you can find them, recycle them.
I looked for the cats on and off for a while, most people just toss them. Looks to be in good shape, Nice save.

This save was possibly in the late nineties. I have saved stuff for years in case I might need them later on. Also figure what was once scrap metal would be hard to find later on.