Cracked Exhaust Manifold

[wcdeane]

I know this is a problem with this car, and prayed that it wouldn't happen to me, but it has...right near #2.

Can these be welded successfully? Anyone have a used version? Where might be the best place/price for a new one? R&R procedures? Any advice would be appreciated.

Walt...'91 SE

[okc-esprit]

It can be welded. You need someone familiar with cast iron welding. You can't just weld the crack, the entire manifold needs to be heated up prior to welding. I tracked down a welder through my aviation contacts. I also had it milled following the welding.

Find your local aircraft mechanic, he can probably direct you to a welder that can handle the job.

[Boosted LS1]

Most welders would use 'dissimilar' welding rods for repairing cast iron headers. Don't know how good it is, long term though.

Boosted.

[teigan]

the weld should outlast the part. if it concerns you though, you could always weld a complete new part from bent stainless tubing.

[cross-eyed-twit]

you cynic!

have some faith. my new one has lasted about 4 years and with a bit of care warming up and down should last a little longer... fingers crossed

teigan said:

the weld should outlast the part. if it concerns you though, you could always weld a complete new part from bent stainless tubing.

[lotusespritworld]

more info here on manifolds:

www.lotusespritworld.com/EGuides/EMaintenance/manifold.html

[Paul93Lotus]

Also try these guys....this is who i'll be sending mine to.

www.locknstitch.com

They will heat the manifold in a furnace prior to welding, and then slowly cool it overnight. Quoted me approximately $200 and it is a long circumfernce crack between the turbo mount and #4 cylinder.

[deecee]

I just went thru this whole process with L&S and got a formal education from a hole in the wall Diesel Shop that has been doing these types of repairs for over 35 years.

According to the owner of the company, here's how to evaluate the company that you are considering to do the repair:

The Heating process is essential, the cooling process isn't.

For those skeptics in the crowd...did the foundry cool the original casting overnight, or are you going to slowly cool you exhaust manifold each time you drive?

The Best of the Best will use Cast Iron, the Posers will tell you they use Nickel (turn and run!) and the Old Timers Trick is to use Brass.