Summary
As we all know, the stock exhaust manifold on the K40 is beyond terrible. I downloaded and modified Bullar's original design but to work with a 40mm hose people on the side to reduce the distance the K40 has to be away from the wall. This has been working okay for several weeks but now it's time for an upgrade.
I took Bullar's design again and found a 100mm PVC floor drain grate for the hose adapter (Almost like as seen in the attached, just square ended - not Octagon) at my local hardware store. I then took all its measurements and drew up a standalone file indicating where I'd mark out the drill holes. This was just to be a template but after it was cut out on 1mm card and the holes had been drilled into the PVC grate, I noticed the card template would make a good gasket.
I then applied it to the manifold design and got cutting. I've used 3mm MDF here. The fit was quite tight but a rubber mallet fixed that. I glued up using PVA Glue.
This will then connect to a In-line blower (pictured) using 100mm (4") ducting. Remember to use some sort of foam to create a tight seal to the K40's vent.
