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as any FD owner knows, the stock manifold that connects the turbos to the down pipe is pretty much gaurentteed to crack at some point on the side towArds the back of the motor. I've read some threads saying it can't be welded, some saying it can, and some maybe. Well here is proof it can be done. A old school welder at a shop called "quality welding" in Portland, CT had it done the same day I dropped it off and for a great price. It's solid and the surface is perfectly level. Check out the pics below. I'm bolting it on tonight and can't wait to not here exhaust leak ticking.
After close up
I haven't found just that part of manifold for sale (bolts snap usually when disassembling ) and if even if it's the whole turbo they're all cracked pretty much.. I'll keep u posted on how it turns out
Originally Posted by Brodie121
Sorry, But it's gonna crack again soon. Pretty easy to find a good used part for cheap.
I havent tried the exhaust manifold (I will within the week now that you brought it up). But from what I have gathered from researching and talking to a buddy who is a welding expert (weld inspector, welding instructor at local colleges, ran a welding shop) your best bet is to weld with nikel rod (Ni-99) and to preheat the part and let it cool slowly. I have welded and machined an iron, and will weld and machine the manifold. When I finally get it installed and put some miles on I will report back.
I haven't found just that part of manifold for sale (bolts snap usually when disassembling ) and if even if it's the whole turbo they're all cracked pretty much.. I'll keep u posted on how it turns out
It can be welded but since the twins can be readily found used, its usually not worth the time and effort. Its cast so the key is to pre-heat it and use a nickel rod. Make sure you face the entire mating surface after welding.
your best bet is to weld with nikel rod (Ni-99) and to preheat the part and let it cool slowly. I have welded and machined an iron, and will weld and machine the manifold. When I finally get it installed and put some miles on I will report back.
Yes, I haven't had any cracks to weld on my FD turbos, but on my FC stock turbo I had a friend that is a hobbyist welder weld a turbo exhaust housing for me.
As stated, grind out the crack, pre-heat the housing to dull red, weld with nickel rod, let cool slowly while peening it with a slag hammer to help relieve stress when cooling.
If I had to pay a shop to do all that it would have been cheaper to get another stock housing without cracks and have it machined for the T04 turbo CHRA (it was a hybrid).
The weld held for over 10 years of racing with no problems- of course the turbo housing cracked in some other places in that time (but all were internal).
Back when I was into English sports cars, I had a local shop weld cast iron manifolds on several occasions. He always said the trick was in the pre-heating. Whatever he did...it was a 'one time repair', as I never had it crack again.
Which brings me to think...okay, I wonder if these cast manifold simply have inherent stress in them, which eventually leads to failure, or is it the constant INDUCED stress from the heat cycles that does it? Or perhaps a combination?
