Exhaust Pipe Flange Doesn't Fit?

[New]

Why did I start this on a Saturday afternoon, knowing that the local parts stores are closed until Monday?
I'm in Quartzsite, AZ, 35 miles or more from anywhere.
My muffler needed to be replaced.  One of the local garages was up over $300 when I left.
My old exhaust was welded solid from the cat to the muffler, no flange connection.
A friend gave me a complete exhaust system that he had.
I went to the local parts store and got a Exhaust Pipe Flange/Ring that says it is for a Suzuki 4, 1.3ltr SOHC Eng. 1986-89 among other applications like a GEO and Ford.
The inside diameter is too small and it won't fit onto the exhaust manifold.
Obviously this is the wrong part.  Has anyone else had this same problem? 

[ack]

Here is the nine dollar question:

Is the Exhaust manifold a stock OEM unit??

An OEM exhaust manifold can be identified as being an Iron casting instead of an aftermarket header made of a set of pipe runners welded to a head flange on one end and a combiner flange on the other end.

My bet is that you have an aftermarket manifold!

You have now had your first experience in dealing with aftermarket parts problems at the autoparts store.

Although an aftermarket exhaust manifold has it's advantage (more power, doesn't crack open), the auto parts store "don't not know nothin'" about your aftermarket manifold.

This sort of thing happens all the time. I forgot this simple concept recently when I went into an autoparts store looking for tie-rod ends for my Rocky-Road OTT system. Turns out I needed SAE instead of Metric parts -- which would have been a tough search for the O'Reilly database:

"...Rocky Road OTT? Nothing on the computer like that..."

The solution was to call Rocky Road. The tech guy gave me the exact Moog part numbers and I had my steering system installed the next day!

Your solution is to find the manufacturer of your manifold (not all that tough -- either Thorley or Calmini), call them and order a flange. Even better, do a bit of measuring on the manifold's output flange (inside diameter of exhaust outlet, the distance center-to-center between the mounting holes and the number of mounting holes - three is a good guess on my part ; ) and go to the auto part store to find a match. I bet you find a match very quickly!

Oh, and if your friend's exhaust system is stock (as I suspect it is) it probably would not be a good idea to adapt it anyway as going from BIG to small pipe does not help your engine's performance. Your choices are to either find a good stock manifold (possibly hard to do) or spend some money and have a large-diameter exhaust system made for your Samurai (200-300 bucks but well worth the performance gain!).

edit: I noticed that the muffler shop wanted $300 "to replace the muffler".  You should be able to simply cut the muffler out and replace it cheaply -- UNLESS -- the rest of the system is so beat up that it all needs to be replaced!   

I'd take the truck to another muffler shop (second butte on the left, west out of town  ) for another opinion.

Hope this helps!

[Polie]

is there a logo on the manifold? You may have a DT exhaust!! Hope you found something good!!!!

[JDMFUK]

I had the exact same problem: stock exhaust manifold and new donut gasket from autozone and the inside diameter was too small. I ended up just reusing the original one but it doesn't sound like you have that option. One thing I thought about doing before I decided to use the original was to use a die grinder on the inside but not until it's loose just enough so that you can tap it on with a rubber deadblow hammer. This may get you going until you can get the correct one and if you take your time it may be a permanent fix.

[catfishblues]

For a stock manifold, try Fel-pro # 60566, future # 12-1048. It's the donut gasket for a 350, among others. I can't remember, but it might have a steel sleeve in it. If it does, knock that out, and it fits great. A little loose on the manifold, but it seals fine.

Surly, if you're listening, please place this in the FAQ! Thanks.

[Surly]

Travis or Zippy, if you're listening, please place this in the FAQ! Thanks.

Fixed it for you.

[New]

My exhaust manifold is stock. 
The old was welded solid from the cat to the muffler.  I don't have access to a welder.
I forgot about the new shop on the west end and Yes, they would have done it for half of that, but I already had the newer one and a 400 mile round trip into it.
That said, what am I missing here?  Why doesn't the Fel-Pro #60479, future No. 12-1028 not fit?
Anyone else had this problem with a stock exhaust?
Last resort will be the GM 350.
Steve

[New]

Problem Solved!
The Fel-Pro ID is the wrong size, tell me something that I didn't know!
I went to the part store and they brought out a Parts Master exhaust gasket and it has the correct inside diameter.
It was also $5.25 cheaper.
It also fits.

Parts Master 521857
Replaces the following:
FP-     60566
W-     31360
ROL-  EG24783