Here is the outlet with some lines scribed using the volvo flange gasket as a guide. Using the clearance around the studs to allow movement, I scribed a minimum sized opening, and a max sized one. Depending on which type of turbo will be mounted, either Garrett or Mitsu, I would grind away the excess iron and shape the opening and blend the runners and the merges.

The scribe lines are only a guide; I would not go quite so close in the corners.

And yes, this manifold is cracked...in two places. I will have to sandblast it inside and outside to be able to see just how bad the cracks are. I might be able to use it; and I might have to use it.

UPDATE: I did port this manifold; and I did install it. And it has performed without a problem for nearly 2 years.