21/02/2026
Volvo 240 RHD exhaust manifold
We needed an extractor type manifold in order to get the best from our classic 240 rally car but could not find one which was designed and built properly for a right-hand drive car. The left-hand drive versions, of which there are many, would not fit due to fouling on the steering column.
We developed the current manifold by modifying a decent quality, affordable LHD manifold and testing it thoroughly on the rally car. This process took over a year before we felt happy to supply it to customers.
The process went broadly like this:
We modified and re-welded the manifold to fit without fouling the steering column – this was achieved by numerous cuts and welds and by re-positioning the pipes after the collectors in order to miss the steering column. This was then fitted and tested on a road car.
We then took the modified manifold to a company who specialise in pipe bending using a process that doesn’t deform the pipe curves. Most aftermarket exhaust specialists use a machine that bends the pipe but causes a restriction on the inner side of the bend. This is OK for further down the exhaust system but not as the gases are flowing from the exhaust ports. Mandrill bending isn’t appropriate for this job due to prohibitive cost and the relatively short lengths of pipe involved.
The company copied our welded pipes and produced properly curved primary pipes with minimal distortion and being one-piece, are less prone to cracking compared to multiple welded versions.
The manifold was then fabricated/welded and a jig made which meant additional manifolds could be fabricated in the correct position for a good fit.
The manifold was then extensively tested on the rally car, which is used on forestry stage rallies, in order to test reliability.
We did a back-to-back rolling road test comparing the new manifold with the original cast exhaust manifold. All engine settings were identical, and the fabricated manifold produced an additional 8bhp and 12 ftIb torque. The primary pipes which go 2 to 1 into 2 collectors are as long as possible and of similar length.
When installing the manifold, the steering column shaft needs to be removed for access and can then be refitted leaving the rubber joiner in place, although we converted ours into a solid one-piece design which enhances the feel back through the steering wheel. The engine mounts, particularly the manifold side need to be in good condition, standard are fine, uprated polyurethane type mounts are also OK.
We produce the manifold to order and the time from order to being ready for collection/carriage is approximately 3 weeks, subject to stock.
The finished price for each manifold is £695, and we need a deposit of £195, with the balance being payable when it’s ready. Payment by bank transfer.
You can check us out at our website www.genuinecars.co.uk Volvos are our speciality.