K40 100mm (4") Exhaust Manifold

thingiverse

Here's my take while the glue's still wet. As everyone is aware, the stock exhaust manifold on the K40 is woefully inadequate. I downloaded and modified Bullar's original design to accommodate a 40mm hose, positioning it on the side to reduce the distance the K40 has to be away from the wall. This setup has been working fine for several weeks but now it's time for an upgrade. I revisited Bullar's design and discovered a 100mm PVC floor drain grate that would serve as the perfect hose adapter at my local hardware store. I took its measurements and created a standalone file indicating where I'd mark out the drill holes. This template was initially intended to guide cutting, but after it was cut out on 1mm card and the holes had been drilled into the PVC grate, I realized the card template would make an excellent gasket. I then applied this newfound knowledge to the manifold design and got started with cutting. I used 3mm MDF here. The fit was a bit snug but a rubber mallet smoothed things out. I secured everything using PVA Glue. This setup will connect seamlessly to an In-line blower (as shown) via 100mm (4") ducting. Remember to use some sort of foam to create a tight seal to the K40's vent. Thanks, Bullar!