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Old 11-19-2008, 04:31 PM   #1
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Default Once again, I managed the impossible....

...and cracked a Flyin Miata/BEGi cast iron turbo manifold. Never really heard of someone managing to crack one of these before.On occaion I have seen some Greddy and AVO manifolds get cracks because of the lack of relief cuts (thermal expansion). But the FM has them designed into the manifold. I did call FM and as expected it's out of warranty. So now i'm waiting a call back from Keith or Bill for special pricing on one of their new manifolds since they don't carry this one anymore. Unfortunatly they don't have any in stock at the moment

To add to the list of things I have broken including a PPF, an intake camshaft (my 96), 2 transmissions (my 96 and my 99), snapped a few swaybar end links, and popped my dipstick out which caused oil to cover the exhaust and catch fire.

Picas!!!

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Old 11-19-2008, 04:34 PM   #2
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You weren't kidding, you cracked the heck out of it. You could get the BEGI replacement instead of the FM one. The new BEGI manifold has zero recorded cracks I think, well maybe that one but their say someone caused that crack. Bet they have them in stock as well.
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Old 11-19-2008, 04:35 PM   #3
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stop being so hardcore
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Old 11-19-2008, 04:38 PM   #4
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Bet they have them in stock as well.

and if not they can get them cast within the hour....
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Old 11-19-2008, 05:30 PM   #5
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OK, so just got off the phone wil Bill @ FM. I'm getting one of the new design manifolds..and they're going to drill/tap it for 10mm hardware and include new 10mm hardware for $425 shipped. So that'll be here soon and now i'll need to either order my 2871 or tap my current turbo for the 10mm studs.... but it's sounding like i'll be getting the 2871.

w00t.

Here is what the new manifold will look like

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Old 11-19-2008, 05:33 PM   #6
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buying a 2871 is much easier than drilling out four holes!
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Old 11-19-2008, 05:37 PM   #7
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I love that casting on the top of the mani, super sweet.

May i ask how the heck you break all this ****? Like a PPF.. Thats insane!
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Old 11-19-2008, 05:57 PM   #8
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And the 2871 still has to be drilled out...
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Old 11-19-2008, 06:10 PM   #9
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hmmmm congrats i guess? look on the bright side i just gave you some added cash flow
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Old 11-19-2008, 06:10 PM   #10
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I'd take the manifold you've got and fix it / get it fixed. That'd probably save you $300..
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Old 11-19-2008, 06:20 PM   #11
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I'd take the manifold you've got and fix it / get it fixed. That'd probably save you $300..
I'm not going to risk trying to fix a cast manifold.
Besides, i've been wanting to upgrade the turbo and this is my motivation.
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Old 11-19-2008, 06:24 PM   #12
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How much do you want for the cracked one? I'm in for cheap.
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Old 11-19-2008, 06:51 PM   #13
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oh, it'll be in the FS section as soon as I get it off the car....possibly along with a gt2560 turbo....
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Old 11-19-2008, 06:53 PM   #14
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hmmmm congrats i guess? look on the bright side i just gave you some added cash flow
you sure did!
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Old 11-19-2008, 07:05 PM   #15
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Originally Posted by cjernigan View Post
You weren't kidding, you cracked the heck out of it. You could get the BEGI replacement instead of the FM one. The new BEGI manifold has zero recorded cracks I think, well maybe that one but their say someone caused that crack. Bet they have them in stock as well.
You would be correct. The one reported failure in the UK was from too much ignition retard.

Based on the photos, I would say that the timing is retarded way too much. That is the location the manifold will crack when there is a timing issue. So the OP might check your Engine management or timing belt for a failure.
Stephanie
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Old 11-19-2008, 07:09 PM   #16
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Originally Posted by Doppelgänger View Post
I'm not going to risk trying to fix a cast manifold.


Do you have any idea how many cast iron Ford E6 turbo manifolds I've welded up? Those pieces of **** crack like glass and its super easy, they all do it in the exact same spot.

Drill your crack ends, V out the crack with a grinder. Bake in oven for an hour at 400 degrees and Use a high nickle rod w/a stick welder, weld the ****** shut. Immediately drop into a bucket of calcium carbonate for the remainder of the day. Viola! For extra structure I was taking them to my brothers work to be placed on a machine similar to a paint shaker, but its a stress reliever. I bought turbo ford manifolds for scrap, fixed them, then resold them. Never had one come back.
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Old 11-19-2008, 07:36 PM   #17
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Quote:
Originally Posted by Stephanie Turner View Post
You would be correct. The one reported failure in the UK was from too much ignition retard.

Based on the photos, I would say that the timing is retarded way too much. That is the location the manifold will crack when there is a timing issue. So the OP might check your Engine management or timing belt for a failure.
Stephanie
Well, Stephanie, if this is part of the problem, then it will be addresses when I get the new manifold on and the 3" exhaust and have the car re-tuned (and when it gets re-tuned, i'll tell him to be a little more aggressive with the timing).
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Old 11-19-2008, 07:43 PM   #18
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I once looked at FM's factory timing map for boosted engine's. It's crazy retarded. And high EGT's do a number on the exhaust valves and seats as well.

Sounds like you can tear up anything.
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Old 11-19-2008, 07:53 PM   #19
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Quote:
Originally Posted by elesjuan View Post


Do you have any idea how many cast iron Ford E6 turbo manifolds I've welded up? Those pieces of **** crack like glass and its super easy, they all do it in the exact same spot.

Drill your crack ends, V out the crack with a grinder. Bake in oven for an hour at 400 degrees and Use a high nickle rod w/a stick welder, weld the ****** shut. Immediately drop into a bucket of calcium carbonate for the remainder of the day. Viola! For extra structure I was taking them to my brothers work to be placed on a machine similar to a paint shaker, but its a stress reliever. I bought turbo ford manifolds for scrap, fixed them, then resold them. Never had one come back.
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Old 11-19-2008, 08:15 PM   #20
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Too bad you don't have a way to monitor EGT.

Did Ed even do any load based tuning, or was it straight WOT power pulls?
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