I've had a lot of issues with exhaust leaks at my manifold. Abe sanded it after finishing the welding, and it came off warped the first time I removed it. Had it belt sanded, and it warped again the next time it was off. Had it touched up a 3rd time, and now I'm getting an awful ticking sound.
I'm trying to figure out if its an exhaust leak or bearing issue.
It doesn't make noise at cruise or decel, only when the throttle opens.
Feels absolutely amazing despite noise. Many of you may have seen in my build thread that the turbo flange was pretty warped. After fixing that, although the ticking developed, it feels much more punchy at lower RPMs. Side mount SR20 Artech build
Seems to have a bit of a whistle along with the clicking.
It seems to go away once warmed up, and is a little worse when really cold.
I'm using a three layer exhaust gasket that's ~6 months old. Two thin "bubbled" layers on the outside and one flat thicker sheet sandwiched in between.
I cannot find any leaks or cracks in the manifold, and the flange doesn't seem warped at all. I'm stumped.
I always get three pieces when I buy a new one. The thicker one with a thin one spot welded to it, and a separate thin one on its own. I've tried just the two piece one, and currently have all three layers installed, no difference.
So I finally got tired of it and took it apart again. Here's the manifold at a few different angles, since it's hard to photograph.
And the head:
If you can't tell, it's leaking pretty bad from cylinder #4, and #1 a bit. So the manifold is bowed.
Here's the ends of the manifold. 1st pictures are just sitting there, 2nd set of pictures is with the opposite end pushed down against the workbench.
Before anyone asks, yes I realize my workbench isn't a perfectly flat surface. But I can repeat these results at any angle on the work bench, on the garage floor, and any other flatish surface I can find.
Should I get it sanded again? Or have it chopped off and a new flange weleded on?
Curly, it looks like as that manifold ages, it wants to pull #1 and #4 inward -- hence the bowing/leaking. Maybe you should make some relief cuts in the flange to let it move? I know on my Greddy manifold with relief cuts, what was originally 1/16" gaps have completely closed up -- but no exhaust leaks or cracks.
One other thing that happened to me is that when the relief cuts closed up, they also caused the hole with the relief cut to grip the stud. Made getting it off difficult. My machinist buddy redrilled the holes to make it easy to install/remove again. I'd keep an eye out for that.
We'll see how this goes. Middle two runners seemed fine, so I only cut between 1&2 and 3&4. It's at the shop now to be belt sanded. Missed the machinist by 15 minutes, otherwise I'd be showing y'all pictures of the finished product.
Edit: yes hornetball, my greddy did that. I drilled the holes out before selling it. If that happens to this one, I'll do the same. My cutting left a decent sized gap, I certainly hope it doesn't close all the way up.
Yikes I have an artech side mount setup in the garage waiting to go on this summer. All your manifold problems makes me nervous! Hope this works. If it does, maybe I should do some relief cuts in mine before I install everything...