Thanks Bill, Louie if you have any questions just yell at me.

thanks.i was just wondering what grit and how you surfaced it.all i can thinkto do is get a finer grit wet sandpaper and lay it flat and hold the flange flat and run it on the sandpaper till its flat and smooth not taking to much off after itlooks good.or you would most definatly need larger orings.and where do you get your orings.they look to be the same as what you would use for hyd. flanges?is this a close idea to what you do?i do have access to a granite table for a flat surface?
thanks for the help.

You can still use the OEM o-rings as all your doing is removing just a little of the crummy surface that the OEM manifold has. Any wet or dry paper between 200 - 400 is good you can start with the course and use oil and do it in a figure 8 until you see no more dark areas the finish off with 400. If you use the over size o-rings you have to cut the nibs out of the o-ring groves. Do a search for oversize o-rings in the tech articles and it will give a lot of ones you can use. Don't use the Ace Hardware ones as the melt after time from the heat. Yes I tried them I use the NAPA ones. If you can't find the o-ring I have a supply of spares that I will sell you a set for my cost plus postage $4.00. I surface mine on a 4' x 7' glass table but you can use the wifes granate counter top if she doesn't catch you.

wish i had a granite counter top.lol we have them at work for surfacing waterjet parts for our robots and for vinear gauges so i can get them flat and not rounded.you sure did help me out and so did everyone that replied with links on the clinic.i love this site for all the help.
thanks to everyone i will post how it goes in a couple days.

Hey everyone, and Curt especially, I just found my rear cylinder is leaking. I ported the manifold a few months ago myself, carefully surfaced the flanges on glass with 400 grit, and I'm using the Napa oversize O-rings.Ground out the nubs and everything.

Has anyone had leaking even with the oversize o-rings? And if so, what's next? What do I do with this thing? Please Help!!!!! Before I shoot it!

I know at least one member got some high temp gasket material at the auto parts store and made gaskets and didn't use the O-rings. last I heard it was working well.

Thanks Dave....I guess I could try that. I'm just bummed that the oversize o-rings didn't do the trick. Fairly big job to get back in there, and I don't want to be doing this every three months. I WILL shoot it if that's the case!

I think shooting your R* is against Clinic code of conduct.

Use some flat washers on the manifold bolts to spread the torque over a wider area that will help some.

well, thanks Curt but I'm headed a different direction for the moment.

I've made some gaskets out of FelPro high temp gasket paper and I'm going to run it tomorrow to see how that works.

When I got in there earlier today I could see that the portion of the flange directly under the bolts was flush with the head, but I could see a gap where the o-rings were. In other words, can't tighten the bolts any more, and the o-rings are bulging the manifold away from the head. Not good.

So, I see where washers would be some help here, but I thought I'd try for a permanent fix.

Will report back