I just finished a page on my recent manifold straightening adventure. Looks like I need more practice.

http://dauntlessgeezer.com/DG82.html

So i think you can just build that hole up with some brazing rod.

Steve, handy as you are, get some welco #800 flux and use some of your old cast iron rings and you can weld that up with your torch. KB

Nice page on the manifold jig Steve.
A few years ago I made one very similair to the the one from the Tulsa club page.
It turned out OK but I think I would buy a new one the next time around due to the cost of the amount of Oxygen I had to use.

When I did the manifold I had I heated the whole manifold from end to end and then heated the area cherry red that needed straightening.

Since your manifold looks like it has very good threads I would try to braze up the hole. It would be good practice to try.

I did my manifold using Kim Dobbins jig a few years ago, and it worked out fine. The weight of the wrench is enough to straighten the manifold. Don't use force! On the last one I did, I had to put a thin washer at #1 and #4, so #2 & 3 would go down a tad lower, because after the manifold cooled, it still didn't line up perfectly.

Had a friend that had a wood stove in his shop.
He would (Start a fire) when going good would (use tongs)put in manifold, when it was the correct color(don't ask what that is) would remove and put in gig and let it cool slowly. A few mite break but most were good.
my 2 cents worth

Bob

I would agree with Larry. Found that cutting four plugs that fit the exaust holes on a T block put them in the block and weld a 1/2 inch pipe across front to back makes an easy way to align the manifold without useing a straght edge. The pipe with the plugs welded to it shows fast and easy where put heat in the right place.
Also found its best to do it twice cooling the manifold let it warp slightly then correct it.

kieth g b,
Could you verify that number for me? About a month ago, I tried to order that flux through the local welding supply, they went to Harris-Welco who had some trouble with the number (800? 600?). After some more contact, they replied that it didn't matter anyway because due to a company merger (confirmed through reports via Google) the product has been discontinued. They wouldn't offer any suggestions for an alternate product. I was right there while the local guy talked on the phone with the company rep. You just have to love good customer service. At least my local guy was trying.
Any other good suggestions?
Drive carefully, and enjoy, W2

get some mule team borax to weld cast iron.
Wieght of wrench is ALL you need to use.If you as much as pass gas near that wrench,your manifold is junk.

Wayne, It may have been that I got the last can they had in stock at my local welding supply, can says harris welco- welco flux#800. It's been two years since I bought this can, should last the rest of my life. I did find another brand on the internet once but don't remember the brand name and did'nt order as I found it locally. They did say it was'nt called for much now a days. I guess I'm old school as they were trying to sell me some silicon bronze wire to weld cast with my mig, have to use pure argon I think. Good luck , KB

Wayne, I just did a web search, found a vender on ebay that carries peterson flux and rods,buy it now price. KB