cracked 4-1 manifold, anyway to repair?

1. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

   #1 5th June 2010, 10:09

   Popped the car up in the air this morning as it sounded like the exhaust was blowing.
   
   Found that the exhaust manifold is cracked on the side oposite the lambda sensor where the four pipes go into one. (GMC btb jobbie)
   
   Took it to the local garage that has done welding before for me and he said he wouldnt touch it as its too thin.
   This true? anyone had one repaired before?
   
   Gavin
2. user_35312 Established Member Joined: Jun 2009 Coventry CV6 Posts: 2477 Slowda Octavia vRS SOLD - Cam'd Chip'd VTR

   #2 5th June 2010, 10:19

   Quote:

   Originally Posted by gavin_t Popped the car up in the air this morning as it sounded like the exhaust was blowing. Found that the exhaust manifold is cracked on the side oposite the lambda sensor where the four pipes go into one. (GMC btb jobbie) Took it to the local garage that has done welding before for me and he said he wouldnt touch it as its too thin. This true? anyone had one repaired before? Gavin

   Done up a turbo mani at work (foreigner lol) needed a little bead, held up fine.
   make sure you use the same sort of weld though, when we first got the mani someone had tried to weld it using mild steel, not good when the mani is stainless.
   
   get some pics? Depends on the severity and location of the crack
3. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

   #3 5th June 2010, 10:21

   will wack up a pic
   
   its about 1 to 2cm big if that. mild steel manifold btw
4. user_35312 Established Member Joined: Jun 2009 Coventry CV6 Posts: 2477 Slowda Octavia vRS SOLD - Cam'd Chip'd VTR

   #4 5th June 2010, 10:22

   Quote:

   Originally Posted by gavin_t will wack up a pic its about 1 to 2cm big if that. mild steel manifold btw

   Sweet okay mate! by the sound of where it is it shouldn't be massively hard as a temp fix.
5. axsaxoman Saxperience Forum Bum Joined: Jan 2003 Scotland Posts: 3380

   #5 5th June 2010, 11:41

   If you see it -it can be repaired --but how old is it --we been making these for over 10 years -and is the g/box bracket attched ?
   if it has riped around the bracket ,then problem is your engine mtgs are soft and its been flexing too much
6. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

   #6 5th June 2010, 17:31

   yer bracket is attached, it has cracked near there. Will get a picture tomorow. Been in touch with a mate who is pritty handy with a welder and he thinks he can sort it.
   
   
   No idea on the age as it was on the car when I bought it. So its at least +2 years
7. r33ryan Infrequent Poster Joined: Oct 2009 Posts: 133

   #7 5th June 2010, 18:48

   to do a proper job you need to g weld over the crack, flush it back off then weld a compersator plate approx 30mm square over where the crack was, then fully weld it, you will need a set of rolls the roll the plate, any 1 can blob it up and butcher it, for top job that wont come back do as above
8. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

   #8 5th June 2010, 20:44

   Sounds pritty tec, where would be good to try for something like that?
9. r33ryan Infrequent Poster Joined: Oct 2009 Posts: 133

   #9 6th June 2010, 14:17

   me im a welder fabrictor lol, try a local welder/fabricator its only a hour or so max but worth doing properly so it dont come back
10. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

    #10 6th June 2010, 21:31

    yer true
    
    heres the crack (small black line under the bracket with the lighter colour under it)
    
    
    
    
    
    I checked the bracket on the gearbox and it was tight so thats not the reason it cracked
    
    
    popped some exhaust paste on for the mo until I find a place to weld it
11. user_35312 Established Member Joined: Jun 2009 Coventry CV6 Posts: 2477 Slowda Octavia vRS SOLD - Cam'd Chip'd VTR

    #11 6th June 2010, 21:35

    Quote:

    Originally Posted by r33ryan to do a proper job you need to g weld over the crack, flush it back off then weld a compersator plate approx 30mm square over where the crack was, then fully weld it, you will need a set of rolls the roll the plate, any 1 can blob it up and butcher it, for top job that wont come back do as above

    Yes! This is very good advice, it stops cracking when the material relieves after welding as that temperature can take it outside of it's yield point
12. gavin_t Established Member Joined: Jun 2009 Southend, essex Posts: 2079 1999 mk2 VTS EP3 2004 civic type r

    #12 7th June 2010, 21:34

    will ask these points when I speak to people, cheers lads