WHY the hell is my exhaust manifold leaking????? - Page 2 - Miata Turbo Forum - Boost cars, acquire cats.

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Old 03-25-2010, 02:54 AM   #21
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do you still have your egr pipe connected? if so it may be putting pressure on the manifold when your tightening it up not giving a full seal, it wont show up until the gasket blows which sound like whats happening, i removed my egr pipe as it got in the way of my reroute....

just a thought, check to see if your faces are true, if they are something is holding it from getting a good clamp, my guess egr pipe

thank me once its fixed
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Old 03-25-2010, 05:04 AM   #22
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They didn't want to fail you again and feel your wraith. that's the way to do it!
I pimp-slapped the **** out of my nuts.
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Old 03-25-2010, 08:42 AM   #23
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I pimp-slapped the **** out of my nuts.
I have the ketchup effect girl do that for me.



Vlad, I would put a machinist's straight edge on your head....can't hurt, and will tell you real quick if all your problems are manifold related before you go about making relief cuts, resurfacing, or reworking runners.

If the head is straight and outer cylinder leak sounds like a runner problem. I would say hustler could be right in this case, and that it's a metallurgy issue. I loved your DIY mani, but you may have just the right lengths and structure to cause more expansion in the center cylinders than the outer ones.
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Old 03-25-2010, 10:05 AM   #24
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Originally Posted by sprx3 View Post
do you still have your egr pipe connected? if so it may be putting pressure on the manifold when your tightening it up not giving a full seal, it wont show up until the gasket blows which sound like whats happening, i removed my egr pipe as it got in the way of my reroute....

just a thought, check to see if your faces are true, if they are something is holding it from getting a good clamp, my guess egr pipe

thank me once its fixed
Don't have an egr pipe
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Originally Posted by gospeed81 View Post
I have the ketchup effect girl do that for me.



Vlad, I would put a machinist's straight edge on your head....can't hurt, and will tell you real quick if all your problems are manifold related before you go about making relief cuts, resurfacing, or reworking runners.

If the head is straight and outer cylinder leak sounds like a runner problem. I would say hustler could be right in this case, and that it's a metallurgy issue. I loved your DIY mani, but you may have just the right lengths and structure to cause more expansion in the center cylinders than the outer ones.
Didn't have time last night, but today I'm taking a straight edge to EVERYTHING. (and I do mean everything)
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Old 03-25-2010, 10:31 AM   #25
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(and I do mean everything)
It's natural to have a little bend in it....

*but it shouldn't pull to one side or another, unless you seriously favor that hand
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Old 03-25-2010, 02:02 PM   #26
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This should not be the issue, when on track we are doing back to back to back to back pulls for 20 min straight, and i am yet to warp my absurdflow setup.

The absurdflow setup does not have relief cuts on the flange either.
absurdflow setups come pre-warped I can't seem to figure out how to fix that yet. Bolting it to a spare cyl. head while welding doesn't help much :(
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Old 03-25-2010, 02:25 PM   #27
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pre heating the metal before welding it?
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Old 03-25-2010, 02:45 PM   #28
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F-it, I let the end user deal. Ha. suckers.
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Old 03-25-2010, 03:08 PM   #29
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F-it, I let the end user deal. Ha. suckers.
At least you admit it...
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Old 03-25-2010, 03:22 PM   #30
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F-it, I let the end user deal. Ha. suckers.
just start off with a warped flange, by the time you're done welding it the sucker will straighten out
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Old 03-26-2010, 01:50 AM   #31
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ok so it looks like the gasket is pure **** and its the stock metal one. its all fuxorzed/deformed and looks like its leaking from #4 and coming apart.. The flange looks straight, but I haven't put a straightedge to it yet. Everything else looks good/decent.

Any recommendations on a GOOD gasket? Should I just replace with another stock metal one, or get a composite, or some other ****?
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Old 03-26-2010, 01:57 AM   #32
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How thick did the flange end up being after milling?
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Old 03-26-2010, 02:10 AM   #33
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Ok the problem is much worse than I thought. Or so it seems:

It looks like its coming from the tops of 1 and 4 and bottoms of 2 and 3:





flange thickness is still pretty darn decent IMO






gasket is all deformed and done
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Old 03-26-2010, 02:19 AM   #34
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Its doubtful its a warped cylinder head but check anyway. Is the flange warped? If not, try another gasket and torque evenly. If it happens again then it could be a design flaw. Interesting that it started leaking after 4 hard pulls. Either burnt out the gasket or uneven heating in the manifold causing warp. You are using a mild steel flange with stainless weld-els correct? Speculating here, but the stainless elbows could be pulling on the flange at a different rate causing the mild steel to conform to the SS's pull thus creating massive gayness.

Last edited by SKMetalworks; 03-26-2010 at 02:23 AM. Reason: Clarity was needed
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Old 03-26-2010, 07:54 AM   #35
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Cleaned, matched injectors?

Sorry, I forget, and am too lazy to check.
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Old 03-26-2010, 08:57 AM   #36
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i'd take the manifold to a shop to resurface, maybe use a little bit Rutherland on the gasket. I use that thing everywhere and it works.
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Old 03-26-2010, 09:42 AM   #37
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If it keeps causing problems I'd say the stainless could be at fault. Stainless expands at a high rate doesn't it?
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Old 03-26-2010, 10:14 AM   #38
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Originally Posted by SKMetalworks View Post
Its doubtful its a warped cylinder head but check anyway. Is the flange warped? If not, try another gasket and torque evenly. If it happens again then it could be a design flaw. Interesting that it started leaking after 4 hard pulls. Either burnt out the gasket or uneven heating in the manifold causing warp. You are using a mild steel flange with stainless weld-els correct? Speculating here, but the stainless elbows could be pulling on the flange at a different rate causing the mild steel to conform to the SS's pull thus creating massive gayness.
Yes, I do believe the weld els are stainless while the flanges are mild. If that's whats causing it then I am completely screwed


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Cleaned, matched injectors?

Sorry, I forget, and am too lazy to check.
yes on both.
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i'd take the manifold to a shop to resurface, maybe use a little bit Rutherland on the gasket. I use that thing everywhere and it works.
Got a link to the stuff? Is it some sort of goo similar to gasket maker or what not?





I really think a lot of my problems are due to excessively overheating the manifold due to running too rich and having WAYYYYY too conservative timing.

I'm going to resurface this thing again (if it needs it), throw in a stronger/thicker gasket, torque it down less and more evenly (hopefully) and try to retune this weekend for more timing and more optimal afr's.

Its a lose lose situation: you tune rich to stay safe to not melt another piston and you have to deal with this bullshti
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Old 03-26-2010, 10:33 AM   #39
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I'm going to resurface this thing again (if it needs it), throw in a stronger/thicker gasket, torque it down less and more evenly (hopefully) and try to retune this weekend for more timing and more optimal afr's.

Its a lose lose situation: you tune rich to stay safe to not melt another piston and you have to deal with this bullshti


Seriously don't be afraid to.

If it makes you feel better I tune for 12.3:1 AFRs, and run Braineacks timing table with a few more degrees here and there. That's before turning the WI back on...

I am considering trying hustler's timing table, but would definitely richen up the fuel map before I did so.


Anyhow, point is: You've got more room to play around than you think. People with bandaids or minimal tuning skills with MS need to be super conservative. You've got an even better ECU...and hopefully better than average knowledge.

Det cans help too.
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Old 03-26-2010, 12:14 PM   #40
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Most fabricators use mild flanges on stainless manifolds cause they tend to warp less both when welding and on the car. I don't think that's the problem. They used a mill to resurface it, not a belt sander, right? Did you weld the head flange last or the turbo flange last?
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