Automotive/!958 Edsel E-400

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Expert: - 10/30/2007


Question
I recently had a total engine re-build. After attaching the exhaust manifold to the heads using the metal like gasket which came with the gasket kit,there seemed to be excessive exhaust noise. After driving, there was a lot of "soot" on the fire wall and ariund where the mainfolds and heads attach. I looked at the shop manual which (to my and everyone else I talked to suprise)said "The mounting surface is machined and does not require gaskets." Later it states to "coat the mating surface of the manifolds with a light film of graphite grease." and bolt it down.
Is this right? No gasket? I have seen at least 3 parts suppliers which list a gasket set for the Edsel Pacer. Should I get one of those gasket sets or just go without one?
Thanks for any advice in advance!
FRED

Answer
Surprised I didn't hear from you via the "E-team" site!  Anyway, my FE-block 361 definitely uses soft-metal exhaust manifold gaskets, and most after-market suppliers of gaskets (Victor, for example) do supply them.

The idea of a gasket is to fill in the imperfections that almost always DO exist between two surfaces.  Surfaces that are initially machined to a close tolerance and for which the joint relies on a reasonably-spaced pattern of robust bolts COULD do without a gasket ... initially!  

My take on this is that, after so many years of wear and tear and so many thermal expansion and contraction cycles, those mating surfaces are very unlikely to be anything close to the fine flat profile they once had.  Too, the manifolds themselves can be warped, and they do not have to be warped by much.

Gaskets will accommodate minor imperfections.  Bigger flaws in tolerance will open gaps that will be beyond the range of gaskets to close.

At this point, your engine being back in, I hope that any issues on the heads themselves are minor, and they probably are.  I have experienced warped manifolds however, and suspect that yours probably are.  Still, machining of the manifold surfaces might accommodate the warp.  Otherwise, you may have to look around for replacements, and judge any that you find very carefully.  Laying the mating surface on a piece of plate glass (generally very flat) can be quite telling; warp will allow some freedom to rock, like a stool with one or two shorter legs.

If these are hard to fine, put the manifolds away and consider a good set of aftermarket headers for the time being.  Not quite original, but the idea is to keep these classics on the road after all!

Good luck, and do keep me posted.

Regards ... EGK

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Ernest (Ernie) Kenward

Expertise

The challenges I most enjoy are thoughtful technical questions of a trouble-shooting nature in both electrical, power electronic and mechanical systems, mainly automotive but also machine control and small-machine PLC applications. Please note, however, that I am NOT a walking shop manual! I DO, however, make it a point to have those manuals and other service literature for those vehicles I DO own, and highly recommend that anyone serious about maintenance or modification of their vehicles do the same; MOST of your answers WILL be found there. For that matter, I do NOT go out of my way to acquire shop manuals for any vehicle I do NOT own! That being the case, any general query to me along the lines of "What is the meaning of this code read from the ECU of my 2015 XYZ?" or "Where is the fuse for the windshield washer pump found?" (try your car's electrical distribution panel for a start!) will not go far. What I do offer is a pretty good collection of literature, insights and hands-on experience with 1950s to 1980's Ford products (plus a developing database of information and practice with the Mercedes diesel cars), along with an engineering perspective and the ability to design and implement custom control, electrical and mechanical subsystems for vehicles. For that reason, I am happy to make my thoughts and efforts available to those who are of like mind and/or are seriously making a point of learning about their vehicles. Use the Opportunity to Learn!

Experience

A key skill in my work and hobby pursuits both is STRATEGIC TROUBLESHOOTING. I am a senior instructor in Electrical Engineering Technology at a leading Canadian polytechnic, my areas being Electrical Power and Industrial Control, electrical and electronics design and manufacturing, and AutoCAD and related CAD/CAE software - plus equipment problem-solving and new equipment design and prototyping. Hobby-wise, I have 30-plus years of experience in auto restoration, mostly in electrical and mechanical systems. Ongoing projects include a 1959 Edsel Corsair, my 1978 Ford E250 class-B motorhome conversion, and the care and upkeep of my Mercedes 300CD. My vehicles become engineering test beds for electrical and mechanical upgrades as ideas present themselves. This includes the design and production of circuit boards to restore or enhance features for which no OEM replacement parts are obtainable, or where better specifications or reliability can be had via newer concepts. Regarding the E250 RV conversion, I designed and continue to revise a custom power distribution system, managed by a Programmable Controller (PLC); this has made most revisions as easy as uploading new firmware as I develop it. The "mini" PLC is a powerful device for custom automotive control systems. One good example (there are many) would be the Moeller "Easy Relay"; these offer a wealth of control, monitoring and variable-and-status display options for such projects. A good example project which has worked well is that one for my RV noted above, which has been on the job - revised in firmware only - for a decade now. It is a load management and charging control system to avoid the sulfation-induced early failure that often befalls deep-cycle batteries used in RV power applications. The battery installed in 2003 lasted long enough to more tnan pay for the PLC that contributed to its longer life ... and the PLC will be there for the next battery as well!

Organizations
IEEE - senior member ... past WCC Student Activities; SME - senior member ... past chair, greater Vancouver chapter chair 318; Edsel Owners' Club - have served in various capacities on chapter executive during seventies; have been Power and Driveline resource on the Edsel Owners' Club "E-team" for more than a decade.

Education/Credentials
Graduate of UBC

Awards and Honors
Certificates of appreciation from IEEE and SME for work in student and chapter activities

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