This is what happens when you stress your manifold:

This is between runner 2 & 3. This is what had cracked before. The white stuff is cold weld, I couldn't tell if it was cracked or not at first, so I applied it and let it cure. After a few minutes of driving a crack delevoped in it.



This is the bottom of runner #1. Notice the cut I had to make in the runner to remove it from the block. I had to pound the hell out of it with a hammer to bend it back since it was warped so bad:



The flange:



Runner #4:

 

BTW, my new manifold and DP are in the finishing stages. It's shipping tomorrow 3-day. Should have it on Wednesday and get my baby all back together next weekend! Then I'll dyno tune her next Friday and go to the track Sat & Sun and see what else I can break.

 

damn homie thats a **** load of cracks!

cant wait to see pix of your new setup

 

Those cracks are running through center of the welds (bottom pics)- that's bad. If those were good welds it would have cracked to one side or the other from the stress. Who made the manifold? - rob

 

I bought the manifold used. It's a JGS manifold. The welds there were grinded down and TIG welded.

 

Did JGS end up doing your new manifold and how did that turn out?

I assume the original welder did a crappy job because every manifold I have seen from JGS has been rock solid. Mine has endured 1400-1700 degree temperatures for nearly 4 years now, with zero signs of quitting.

 

Ouch.

 

I bet that braineack puts his turbo stuff through 10x the punishment of anybody else here because he does track events. It's like a drag racing from corner to corner for 20 minutes straight. I saw one of racing mazda's tubular manifolds crack at the end of it's second 20 minute session at a track event. And it had additional gussets added for strength. It's got to be a combination of the perpetual boost (heat) and the bouncing off of curbs, excessive and repeated load changes. It's hardcore abuse. - rob

 

He should probably go with a cast manifold.

Frank

 

i did. I have a BEGi manifold and downpipe now.

 

I'm just amazed that 9psi through a T3 in a 1.6L is putting that much stress on the manifold. That is a really free flowing setup for that size engine. What are your sustained EGTs?

 

I think it had to do with the DP have no flex they way I had it mounted.



there used to be a bracket there.

 

ahh yes the "lower backpressure mod" thats a nice one.