Let me start this post saying that this engine is on a track car with a standalone ECU. So emissions and CEL/codes are not a concern.

I have a 2008 L61 that unfortunately has the secondary air injection ports open on the head. I have the LNF exhaust manifold and turbo setup that I am adding to this engine. The problem I have run into is that the LNF exhaust manifold does not cover two of the SAI ports in the head.

What options do I have for blocking these ports? Below is the two that are not blocked by the manifold flange.

 

JBweld? Or maybe find a sheet of aluminum and make your own gasket.

 

I don't think JB weld is going to hold up to the exhaust heat.

 

Weld them shut or make your own gasket

 

I didn't either but it's the first thing that came to mind. You could always find a non SAI L61 head. They can't be that expensive from a u-pull it.

 

All the research I've done, it appears that even the Non-SAI heads still have those little square ports next to the exhaust port, and they are open to the exhaust port. It was just the exhaust manifolds that were different from SAI to Non-SAI.

I figure its going to be tough to get that area clean enough to get a good TIG weld to close it.

Its not a large opening, but its right at the edge, I am worried that a custom gasket may not have enough clamping force out there to seal it.

 

Weld it thats the best way

 

just use a gasket that blocks the port i use this one
LSJ Exhaust Manifold Gasket [ZZP]

 

I use the copper gasket that ottp sells, it covers all those holes.

 

No signs of exhaust leaks in those areas?

 

How about that, I don't recall noticing them ports on mine but it's also been, 6 or 7 years since my exhaust mainfold was off. That's a pretty big hole, welding probably is the best bet. Or like three tubes of the gasket maker stuff lol

 

I was originally using the lnf gasket but it leaked like hell. This one seals over the holes.

 

I quit using the LNF gasket for the same reason