D-180 Exhaust

[JamesBe1 84]

Hi Guys. I know this topic has been covered at length for some engines, but I would like to tap into the collective wisdom for my own situation.

I have a couple of D-180's, with Kohler K482's. I am going to swap the engine from the one with the good engine/terrible frame, to the one with the bad engine/good frame.

The problem is that the good engine has trashed mufflers. I am going to have to rig up a new muffler system, but I need to get the old ones off of there. The D-180 exhaust system has flanges that bolt onto the block into which the exhaust nipples are threaded. In another thread, I recounted breaking the engine block using the 'compress the nipple with a chisel method'. Needless to say, I don't want to go near that method again since I don't want to destroy this good engine.

Does anyone have any good tips/tricks/hints/advice for removing the exhaust nipple?

Any help would be appreciated.

Thanx,

James

[Sparky-(Admin) 23,277]

Take a hack-saw blade or use a saw-zall and put the blade inside the nipple and cut a groove in it right to the threads in the block. I did one with two cuts, one on each side wall and it practically fell right out. It only took one small tap and not a big whack. No chisel either. The threads in the block will be fine and a new nipple will still thread right in.

Mike............

[Trouty56 567]

Did you hack saw the old nipple down to the threads in the flange first. I actually used a sawzall (spelling)....cut it at 2 places.

Whoops.....2 late!!!

[Sparky-(Admin) 23,277]

Did you hack saw the old nipple down to the threads in the flange first. I actually used a sawzall (spelling)....cut it at 2 places.

Whoops.....2 late!!!

Great minds think alike Bob!!

Mike...........

[JamesBe1 84]

Gentlemen, I am impressed. And grateful for your input. That is an excellent idea. I never thought of that, but now that you explain it, it makes perfect sense.

I am going to start taking the engine off the tractor tomorrow and put it on a bench to clean it up thoroughly before I install it on the other tractor. It should be a day or two before I get to the sawing part. I'll be using a jigsaw as I don't have a sawsall. If that doesn't cut the mustard (in this case rusty mustard), I'll have to do it by hand. I've been meaning to pick up a sawsall, but never got around to it.

I will let you guys know how it goes. I'll try to remember to take pictures.

James

[Trouty56 567]

Did you hack saw the old nipple down to the threads in the flange first. I actually used a sawzall (spelling)....cut it at 2 places.

Whoops.....2 late!!!

Great minds think alike Bob!!

Mike...........

Mike, I probably picked that technique from one of your posts (I didn't come up with it on my own) so i learned from the best!!

Gentlemen, I am impressed. And grateful for your input. That is an excellent idea. I never thought of that, but now that you explain it, it makes perfect sense.

I am going to start taking the engine off the tractor tomorrow and put it on a bench to clean it up thoroughly before I install it on the other tractor. It should be a day or two before I get to the sawing part. I'll be using a jigsaw as I don't have a sawsall. If that doesn't cut the mustard (in this case rusty mustard), I'll have to do it by hand. I've been meaning to pick up a sawsall, but never got around to it.

I will let you guys know how it goes. I'll try to remember to take pictures.

James

James, the exhaust nipple I cut out of a 60's motor was so rusted that it appeared to be part of the block. This will work!! Saw off the nipple so there is a little bit sticking out for you to tap a little with a punch if needed to break it out. I really think it is documented on here with pics somewhere. Don't hurry and take pics. No worries!!

[JamesBe1 84]

Ok, got my exhaust off this afternoon. Not too bad at all. I didn't have a sawzall, but I had a jig saw with a metal cutting blade. Good enough.

Here's a pic of the engine before I started:

I cut the first exhaust off with a hack saw:

I cut three slots into the nipple and used a hammer and chisel to collapse one of the segments inside the port. I cut it deep enough so that the segment pretty much fell away from the other two:

The second segment easily collapsed into the port:

After that, just a few taps with the hammer and chisel, and the last segment came loose. Here is a pic of the nipple posing on top of the flange:

I cut the second exhaust off, but this time, I left a few extra threads sticking out. It was very difficult to get the hacksaw in with enough throw to cut, so I ended up taking the blade off of the frame, and cutting with with just the blade:

Again, I cut three segments into the nipple. This time, there wasn't as much room as on the other side. I could barely get the jig saw in place to cut with. I guess I got a little impatient, and didn't cut as deep as I should have. Still, after gently collapsing it with the hammer and chisel, it collapsed into the port. The segments weren't completely separated, but they were weak enough that it folded in on itself. After I got two of the segments to collapse, the third segment came loose on its own. I was able to turn it with a wrench to take it out.

The whole event took a little over an hour (not counting taking the horse out for grass (sorry, not pictures of that this time)).

All in all, yous guys (as we say in NJ), saved me a lot of effort. I can't thank you enough. Beers on are me.

[Trouty56 567]

Nice job James. They were pretty rusted!!

[Sparky-(Admin) 23,277]

Beers on are me.

I know you said alot of other stuff but this is all I heard!!

Glad to hear you got it done!

Mike................

[tech270154 8]

 

Did you hack saw the old nipple down to the threads in the flange first. I actually used a sawzall (spelling)....cut it at 2 places.

Whoops.....2 late!!!

Great minds think alike Bob!!

Mike...........

 

i know this job was attend last year but i was just reading it now .

i am very proud of you Mike,you would be a very good service plumber,because this a technique that that we applied on rusty pipe when

avoiding wrecking   "the good side" i am a retired plumber from number years ;

and congratulation to you James to attend a  such of tricky job like that

 

i own also a d-180  k-482

yves     from  Quebec Canada

[JamesBe1 84]

Thanx Yves. 

 

We're all just learning here.  Sometimes I get to learn new and better ways of doing things, and sometimes I get to share them.  Usually more of the former.

 

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