I currently sit on the fence. I don't feel like pulling my turbo unless I have an issue. I've had waaaaaay too much downtime on my car with problems to want to do this when it's not a proven issue.
Cracks in a cast exhaust manifold are considered normal, particularly on a turbo car. What people are referring to on the stage 3 is nothing we should be worrying about. This is (yet another) situation where a harmless issue gets blown out of proportion on the fourm.
I recommend a cool-down period or turbo timer to impede their progression.
High heats, and heat cylcles contribute to the high rate of cracks. Tubular steel manifolds have often been used to combat cracks. These, in order to not crack, have to be very thick and just as heavy as the stock cast manifold, but obviously takes a lot more man-power to produce. Obviously, any car manufacturer will chose cast.
This is for info only, and I will delete any negative responses.
I agree 100% with this. I have been laughing about it for awhile now. I have about 10 stock manifolds sitting here, only one isnt cracked.
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This is a nice little read: http://www.locknstitch.com/CastIronWelding.htm
(make sure you also read about expansion and contraction at the bottom, and that will lead you to further pages full of explanations )
I don't know what the process people have used on our manifolds, but I know it's a last resort and normally you have to use low heat to perform a weld. This cast part will go through a lot of heat cycles so I don't recommend welding on it. I'm sure there are experts out there that are better equipped to answer the questions... but from what I understand and what I've read, it's not the best idea.
Thank you sir, may I have another lol.
So then it sounds as though welding in a ramp to deflect more of the exhaust gasses onto the turbine blades is extremely risky...if the ramp weld came unbuttoned, then the turbine blades are history...
So then it sounds as though welding in a ramp to deflect more of the exhaust gasses onto the turbine blades is extremely risky...if the ramp weld came unbuttoned, then the turbine blades are history...
If done properly, it's not just a bad idea, but I would be very leary about it. Personally.... I wouldn't do it, but that's just me. I like the stage 3 turbo as is. Doesn't mean anyone is right or wrong to do the weld mod... but for me, it's a lot of hoopla for nothing.
How long has stage 3 been out and now we're hearing about these manifolds? How long before we hear "my weld came apart from the ramp and my stage 3 is junk." Hopefully never, but I'm not about o jump on the bandwagon quite yet. But as all the shenanagins in my forum, this is just my personal opinion.
If done properly, it's not just a bad idea, but I would be very leary about it. Personally.... I wouldn't do it, but that's just me. I like the stage 3 turbo as is. Doesn't mean anyone is right or wrong to do the weld mod... but for me, it's a lot of hoopla for nothing.
How long has stage 3 been out and now we're hearing about these manifolds? How long before we hear "my weld came apart from the ramp and my stage 3 is junk." Hopefully never, but I'm not about o jump on the bandwagon quite yet. But as all the shenanagins in my forum, this is just my personal opinion.
I agree...sometimes it's better to be cautious...wait and see...don't jump on the bandwagon just because everyone else does. Again, if mine is cracked and fails hard, I'll replace it with something else so my bandwagon will be faster than any shananagin can accelerate from zero to maximum-drama
well doesnt this thread open a whole new can or worms??
We had/have the cracked manifold is going to chip and screw your turbine up threads. Now we have another theory out there, leading people to believe their welding is going to come apart and destroy their Turbos as well.
I really wasn't trying to open a can of worms nor place the laurels around any particular winners neck. Welding cast iron was never considered good practice at Royce's and I was suprised to see it being done routinely here. I hope there aren't problems with the welds cracking, but I guess time will tell.
Last edited by Simon.Starkie : 04-03-2006 at 07:46 PM.
I have heard just tring to match the alloy of the manifolds with a good wire or stick for wielding is a pain. They use an alloy that has a high nickel content and makes wielding a pain. But like Jimmy said there are those that have figured it out. I can only image the stretch and shrinking that take place between cold and orange turbo. Mine has been glowing on a couple occations, and has seen 1800+ degrees celcius EGT's. (stock turbo mine you, not stage 3) That is a lot of change and distortion.
Randy
nice info! does anybody offer replacement/upgraded manifolds for the stock turbo and/or s3? I personally wouldn't want my manifold welded, I'd rather put out the money to replace the entire thing. I live by the philosophy of "if it breaks, upgrade it!"
nice info! does anybody offer replacement/upgraded manifolds for the stock turbo and/or s3? I personally wouldn't want my manifold welded, I'd rather put out the money to replace the entire thing. I live by the philosophy of "if it breaks, upgrade it!"
The stock manifolds are not available seperately despite my best efforts to find a way to get them. Someone could probably build one, but the welded steel ones have to be very thick to withstand the same extremes...so they would be jsut as heavy if not heavier than the cast units.
A new one from mopar would include buying a new turbo as well.
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