Cracked manifold
#1
Cracked manifold
The cast-iron exhaust manifold on my car has developed a large crack (see photo). It's a log-style collector manifold which came bundled with my AVO turbo system and is about eight years old, but has seen less thank 40K miles driven. I've reached out to AVO to see if a replacement is still available, and if so what it costs, but am waiting for an answer.
After searching the forums, it seems these components are prone to cracking - so I'm also trying to figure out what my other options are. I've looked at turbo manifolds from Flyin Miata, BEGI and on eBay, but it doesn't appear that any of them would be a direct plug-and-play replacement for the AVO piece I have now.
I've been told that a cast-iron part like this can be welded, but it takes a fair amount of skill and patience, and that the repaired manifold would remain prone to cracking. I'd like to get a repair estimate from a local welder, but have no idea who to reach out to.
Do you guys have any recommendations?
After searching the forums, it seems these components are prone to cracking - so I'm also trying to figure out what my other options are. I've looked at turbo manifolds from Flyin Miata, BEGI and on eBay, but it doesn't appear that any of them would be a direct plug-and-play replacement for the AVO piece I have now.
I've been told that a cast-iron part like this can be welded, but it takes a fair amount of skill and patience, and that the repaired manifold would remain prone to cracking. I'd like to get a repair estimate from a local welder, but have no idea who to reach out to.
Do you guys have any recommendations?
#14
I had my Greddy manifold welded recently. It had the usual cracks as the prev owner did not make enough relief cuts. I'll let you know how mine works out over time.
To repair it I took it to an exhaust shop and asked the guy if he could fix it. He seemed confident he could. At least that was what he said. When I got it back it was painted black. Presumably because he filled in the crack with a golden colored substance. The paint was to hide the repair. I'm not a welding expert so I can't tell you what it was he used to fill it. Cost was $70. He did mention that since it was cast he would need to braise (sp?) the new metal in to fix it.
To repair it I took it to an exhaust shop and asked the guy if he could fix it. He seemed confident he could. At least that was what he said. When I got it back it was painted black. Presumably because he filled in the crack with a golden colored substance. The paint was to hide the repair. I'm not a welding expert so I can't tell you what it was he used to fill it. Cost was $70. He did mention that since it was cast he would need to braise (sp?) the new metal in to fix it.
#15
I had my FM mani repaired a while ago, and it failed again a few months later.
Yours is pretty easy to reach, grinding the hell out of it and filling it all back in is a plus. Definately a place with an oven, etc, not just some guy who 'can weld anything'.
It's worth a shot, but I'd start saving for a new mani/DP combo. Good time to upgrade turbos, while you're at it. And with the new IC piping, maybe a bigger IC. All that flow, and it'd be a shame not to put in bigger valves. More power means bent rods, so toss in some carillos....
Wait a minute, I thought this was supposed to be cheap. :-)
Anyway, it won't hurt to try.
Yours is pretty easy to reach, grinding the hell out of it and filling it all back in is a plus. Definately a place with an oven, etc, not just some guy who 'can weld anything'.
It's worth a shot, but I'd start saving for a new mani/DP combo. Good time to upgrade turbos, while you're at it. And with the new IC piping, maybe a bigger IC. All that flow, and it'd be a shame not to put in bigger valves. More power means bent rods, so toss in some carillos....
Wait a minute, I thought this was supposed to be cheap. :-)
Anyway, it won't hurt to try.
#19
I had the same AVO which lasted 8 years and 40k miles - I had the center stud, but I had a 1/8" NPT hole and an EGT probe, in the collector where the crack is, and it cracked there. It also cracked a few days after I lost an exhaust support donut and was too damn lazy to check the noise out. :(
I ended up getting a BEGI manifold and downpipe, but lost spoolup. I then got an ETD shorty tubey mani and a custom downpipe, which is now waiting to be installed.
I ended up getting a BEGI manifold and downpipe, but lost spoolup. I then got an ETD shorty tubey mani and a custom downpipe, which is now waiting to be installed.
#20
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Take that sucker off and drill out the ends of the cracks, stop it in its tracks. Use a good cutting wheel on a grinder and V out the crack all the way into the manifold, but don't make it huge. Bake it at 450 degrees for around 30 minutes then use a nickel welding filler and close it up. Do it clean but quick, don't clean the weld.. Drop it into a bucket of powdered Lime and leave it overnight.
Did that to a cracked E6 Ford 2.3 turbo manifold almost ten years ago, still rock solid to this day.
Did that to a cracked E6 Ford 2.3 turbo manifold almost ten years ago, still rock solid to this day.