Well the past few days or so I've been hearing what seemed to be an exhaust leak on the hatch. I checked all of the manifold/wastegate bolts and everything seemed to be just fine. I thought it could have been this bolt I had to replace earlier that has about 20 washers (not really) stacked because I didn't have the right length, but that wasn't it either. Since this didn't solve the problem I began feeling around and could tell that there was a small exhaust leak around the wastegate flange but I couldn't tell if it was between the wastegate flange and the welded manifol flange, or from an actual crack in the manifold flange itself.

Since the car was still hitting full boost I took it to work tonight anyway figuring I would just check out the wastegate mating surface tommorrow when I'm off. Lets just say I figure out what the problem was.

I hit the long bridge to work and thought I could hear the leak getting louder so I decided to tip into the throttle in 5th gear. Boost rose to 5lbs and I watched as the rpms climbed waiting for it to hit full boost. Something told me that by about 5k I should have seen more than 5lbs, just a guess so I let off. Just to be sure I downshifted to 4th and gave it some gas.....no boost. The Civic was back to mizzad NA power and my exhaust got really loud.

Pulled in to work and popped the hood. My Tial was hanging by the vacuum line completely broken free from the manifold. It wasn't the bolts, the stupid manifold flange weld had broken off completely.

Now i have a big hole in the manifold and really don't want to risk burning a valve with it being so close to the head, but I think I can get a ride.

My question is what kind of welder do I need for an iron manifold and flange? I have a stick/arch welder at home that I know how to use (kinda) and wouldn't mind giving it a shot myself.

If I can't do that I just might run it to a place in town and have them weld it up. I don't figure it would take long nor cost anything, but I'm just worried about driving it. Any input?
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Which is it? A welded steel manifold or a cast iron manifold?

 

Iron.

 

can iron and steal be welded togeather?

 

It's an iron flange. It's not the wastegate flange, its the piece of the manifold that the wastegate bolts to. That's what broke off, the wastegate just went with it (obviously).

 

Guys, this is the maxrev manifold.

 

So again I'm confused. The Maxrev manifolds are welded stainless steel. They can be easily repaired. Cast iron manifolds are difficult to repair. Is ActiveAero confused about what material his manifold is?

 

He must be. I built the car, so I am familiar with its setup. If the maxrev mani is SS, then that is what his mani is made of. Obviously it should be repaired by means of a TIG weld correct?

 

The maxrev is SS. You could TIG it, but what's to say it won't happen again. Welds break (more likely with turbo cars due to pressure between the head and turbo).

 

I agree it could break again, but that is the nature of the beast when it comes to welded manis. Besides, if you have a good welder do it, you should be fine.

 

Yeah I'm dumb its steel. The flange however looks like iron (its brown), but maybe that's just me?

Regardless I had it re-welded today. Thanks anyway.

 

Good luck. If it doesn't hold up and you need a new one, Inlinepro or SFP have a good quality/inexpensive manifold that most people on this board like.

https://honda-tech.com/zerothread?id=966979