Hey I know its ghetto, but can i have a welding shop weld my cast iron greddy manifold to my t25 turbo (the bolt holes on the flanges are messed up). I would be able to get one or two bolts in, then weld it. Let me know if this can be done. Thanks

 

why not just cut the flange off and re-weld the correct one on it? no way i would weld a turbo to the manifold

 

If you do weld it on, you will need to weld up, or otherwise seal the bolt holes.

Also...why not just redrill and tap them?

 

Guaranteed cracking

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">Guaranteed cracking</TD></TR></TABLE>

Cracking guaranteed

 

Cast iron can be welded to cast iron...so...why would this be any different?

 

Have you ever tried to weld cast iron to cast iron, especially dirty pre rusted cast iron woohoo not a good thing.

 

no i havent, but there is a welder here in town that specializes in cast iron stuff, so I know it can be done.

 

ok buddy you keep dreaming think of it this way if used cast iron was easily weldable without cracking.

why would honda have piad money to replace thousands upon thousands of cracked exhaust manis every year on shoc civics?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by jcmcnugent &raquo;</TD></TR><TR><TD CLASS="quote">Hey I know its ghetto, but can i have a welding shop weld my cast iron greddy manifold to my t25 turbo (the bolt holes on the flanges are messed up). I would be able to get one or two bolts in, then weld it. Let me know if this can be done. Thanks</TD></TR></TABLE> just make an adapter plate for it , that would be the best way , so you can still remove it from the manifold,

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">ok buddy you keep dreaming think of it this way if used cast iron was easily weldable without cracking. why would honda have piad money to replace thousands upon thousands of cracked exhaust manis every year on shoc civics?</TD></TR></TABLE>
Probably (just speculating) because they'd rather have the consistency and ease of having dealers just swap manifolds than to have them pull them, take them to thousands of different "local" welders across the country, and then put them back on the car. For an individual to do this one time isn't nearly such an issue..but for them, they'd then be responsible for the work of these thousands of welders...and all the inconsistencies involved in their work.

The problem in this specific instance would be that you would be essentially taking two rectangular plates and welding them around the edge. Then the one on the engine side would likely get MUCH hotter than the turbo side, making a huge expansion differential with every heating and cooling cycle. Not only that, but each part will have a different metallurgical makeup that would increase this even more. I would be VERY surprised if this held up for long. The flange does five a small amount of flex between the two, allowing some expansion.

 

I had a guy ask me to do this, I tried to talk him out of it but he was tired of blowing the gasket out on his 300whp K24A 240sx. I figured he should machine the 2 surfaces and just bolt them together but there was no talking him out of it. Sooo, I went to a local welder supply, picked up some cast welding rod(yes stick rod) removed all the flux and fired up the Tig. I then proceeded to heat the turbo and manifold in a home oven up to as hot as it would go(yes I know this isn't ideal, but I don't have anything better). I then welded it, and it welded quite well. We put it back in the oven and let it coll slowly over a period of many hours. The assembly was then raced on and held up until the owner blew his trans. I'm curious to see how long it will last before cracking, but it's been good so far.

 

I never said it was easy, but it can be done.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by civicross &raquo;</TD></TR><TR><TD CLASS="quote">I never said it was easy, but it can be done.</TD></TR></TABLE>
Sure, it can be done. I've welded aluminum to carbon steel before also....but it probably would have broken apart if hit with a hammer.

The question on something like this is how well it will hold up.

IF I was to do this, I'd grind a bevel on both pieces so that I could get more penetration and hopefully get more reliability out of it.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Masta &raquo;</TD></TR><TR><TD CLASS="quote">I had a guy ask me to do this, I tried to talk him out of it but he was tired of blowing the gasket out on his 300whp K24A 240sx. I figured he should machine the 2 surfaces and just bolt them together but there was no talking him out of it. Sooo, I went to a local welder supply, picked up some cast welding rod(yes stick rod) removed all the flux and fired up the Tig. I then proceeded to heat the turbo and manifold in a home oven up to as hot as it would go(yes I know this isn't ideal, but I don't have anything better). I then welded it, and it welded quite well. We put it back in the oven and let it coll slowly over a period of many hours. The assembly was then raced on and held up until the owner blew his trans. I'm curious to see how long it will last before cracking, but it's been good so far. </TD></TR></TABLE>I was just going to bring up Adam Hutchinson's car. Lot's of interesting welding on that manifold. Esp. the wastegate.