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Old 05-19-2013, 03:27 PM   #661
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Aluminum welds are pretty brittle sometimes.
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Old 05-19-2013, 06:09 PM   #662
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Not completely surprising. I would expect it to be fine if you sent it out to be solution heat treated after welding. But that may be pricy and will take a week or two.
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Old 05-19-2013, 06:36 PM   #663
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I would wager the welds were the culprit. Proper prep is key for welding Al. Not to mention the possibility that there wasnt enough penetration, especially if the welder was trying to make the welds "pretty".
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Old 05-20-2013, 12:19 AM   #664
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Quote:
Originally Posted by Full_Tilt_Boogie View Post
I would wager the welds were the culprit. Proper prep is key for welding Al. Not to mention the possibility that there wasnt enough penetration, especially if the welder was trying to make the welds "pretty".
The welds cracked right down the middle. They had great penetration. There is just to much weight hanging and leverage on them.

Maybe the delrin mounts played a role.

We will also be supporting it from underneath with a brace. Gonna make sure we have zero problems going forward.
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Old 05-20-2013, 12:20 AM   #665
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I wouldnt expect the delrin mounts being an issue, the intake manifold is going to see the same vibration from the engine no matter what the mounts are.
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Old 05-20-2013, 12:31 AM   #666
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The welds cracked right down the middle. They had great penetration. There is just to much weight hanging and leverage on them.

Maybe the delrin mounts played a role.

We will also be supporting it from underneath with a brace. Gonna make sure we have zero problems going forward.
I'm not sure what kind of filler rod you used (4043 is most common), but it never hurts to jump up to a higher grade like a 5356 or better. It can make a significant difference.
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Old 05-20-2013, 12:33 AM   #667
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I'm not sure what kind of filler rod you used (4043 is most common), but it never hurts to jump up to a higher grade like a 5356 or better. It can make a significant difference.
Even welding cast? Because **** if any of us know that alloy of the two different manifolds and if they have any sort of heat treat to begin with.
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Old 05-20-2013, 12:41 AM   #668
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we should be welding with a higher quality filler rod then assumed original material.

the areas welded should have also been "V'd" prior to welding.

still, some sort of support brace like the OEM one couldnt hurt.
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Old 05-20-2013, 08:08 AM   #669
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Yeah, for the love of god... All this BS about the welding, just brace the damn thing.
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Old 05-20-2013, 09:16 AM   #670
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Quote:
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Yeah, for the love of god... All this BS about the welding, just brace the damn thing.
Not completely BS.
No one til now has braced these things, and so far we have 2 documented failures: 1 for sure was crappy welding, the other apparently not but who would know for sure?

That said I don't have anything against bracing them either.

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Old 05-20-2013, 09:51 AM   #671
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newbsauces im from begi cracked in thesame way.
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Old 05-20-2013, 09:58 AM   #672
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So 3 then. Ok, starting to worry me lol
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Old 05-20-2013, 11:03 AM   #673
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BP, y u haz to vibrate so much?
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Old 05-20-2013, 11:46 AM   #674
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To be honest I was not surprised it cracked. I just expected it too take longer.

Those that question the quality of the welds or weld material just need to look at how the rest of the car is built to get a reference for the work we do.

Heed the warnings or ignor them. It's up to you.

FWIW V2.0 is being done by the head fabricator at a race shop that services million dollar plus vintage formula one cars. It was his recommendation for the bracing etc.
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Old 05-20-2013, 11:51 AM   #675
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Here's mine



After three weeks



So I fix it....


.....AAaand after first race weekend. Here we are again
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Honda intake manifold-2013-05-07-18.08.21.jpg   Honda intake manifold-20130501_193724.jpg   Honda intake manifold-2013-05-09-17.32.jpg   Honda intake manifold-2013-05-09-19.18.jpg   Honda intake manifold-2013-05-12-14.56.jpg  

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Old 05-20-2013, 11:54 AM   #676
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Non-cracked intake club signing in.

I am nervous now
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Old 05-20-2013, 11:56 AM   #677
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i wouldn't be for yours.
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Old 05-20-2013, 12:40 PM   #678
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I kinda figured. It's really light, good welds and the weight is held closer to the flange rather than being held way off.

I have no idea what I'm doing with my life.
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Old 05-20-2013, 01:15 PM   #679
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yeah the runners are so short .
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Old 05-20-2013, 02:00 PM   #680
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The only way you know your runners are long enough is when you crack your welds. noted
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