when i bought this manifold it was already fixed, there were gussets welded to hold the gate from braking off again. and well i guess it didnt help at all, is this a lost cause of a manifold or can it be fixed again. it was tiged welded but from someone with less then a year under his belt.


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Modified by bart simpson at 6:26 PM 9/14/2008

 

Have any pics of the joint?

 

Maybe he could be using the wrong filler rod, or the EGT's are getting to hot and heating the metal beyond its stable temperatures. The wastegate in most manifolds is pretty restrictive because of the angle the air has to flow through. Where is it cracking at? On the weld itsself or is it the metal breaking apart?

Good luck with it all, and if you end up having to junk it try getting a different manifold (if you can afford it) like a Peakboost, full-race or afi manifold.

 

if it's an ebay tubular manifold, you'll continue to have those problems, no matter how many times it's 'fixed'.

 

If you're running stock engine mounts you could have excess engine movement causing stress on your manifold/wastegate.

 

What exactly is it made with? Schedule pipe (thick) or 16 gauge exhaust tubing?

 

once a manifold cracks it is very hard to clean it enough to remove all of the contamination the exhaust gasses put into the metal. you would have to prep all of the surfaces AND inside the cracked area, which is what most people skip, and when it is welded the crack just resurfaces. welding over a crack is worthless, you have to weld between the crack.

 

ill try to get pics up asap. its a vw 1.8t so fullrace is the only choice. def not an ebay jump off. made from a company that went onto cast only manifolds.. guess they saw this comming.

 

pics up

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by .john. &raquo;</TD></TR><TR><TD CLASS="quote">once a manifold cracks it is very hard to clean it enough to remove all of the contamination the exhaust gasses put into the metal. you would have to prep all of the surfaces AND inside the cracked area, which is what most people skip, and when it is welded the crack just resurfaces. welding over a crack is worthless, you have to weld between the crack.</TD></TR></TABLE>


yes you must cut the old weld out completely......

 

Make sure you're using the same filler material as the manifold.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by TurboSI56 &raquo;</TD></TR><TR><TD CLASS="quote">Maybe he could be using the wrong filler rod</TD></TR></TABLE>
exactly