Announcement

Announcement Module
Collapse

How To Post Images

Want to know the how to upload images to your posts? Image Posting Tutorial
See more
See less

Exhaust manifold repair

Page Title Module
Move Remove Collapse
X
Conversation Detail Module
Collapse
  • Filter
  • Time
  • Show
Clear All
new posts

  • Exhaust manifold repair

    I have had crack in the exhaust manifold on the old combine for some years, I figured it was time to fix it, I have tried to locate a USED or NEW one for the last 5 to 6 years, NO find, I thought I had one it was for a diesel engine not the gasoline version, and it was different enough as it was not even going to bolt up,

    I took off the manifold and considered welding it my self, (most I know do not have much luck welding cast exhaust manifolds, I had no way of pre heating it, so I took it into town, and the welder (new guy) thought he could weld it, NO pre heat just started in on it and basically destroyed it, so I picked up some steel, and headed home,

    and this is what I came up with below, if I counted correctly there are 29 separate parts that needed cut, machined, test fitted, welded, ground, etc,

    It is not the pettiest but I think it will work, (would do a few things different if I was doing it again, but I think it will work fine,



    Push sticks/blocks Save Fingers
    ~~~~~~~~~~~~~~~~~~~
    "The true measure of a man is how he treats someone who can do him absolutely no good."
    attributed to Samuel Johnson
    ~~~~~~~~~~~~~~~~~~~
    PUBLIC NOTICE: Due to recent budget cuts, the rising cost of electricity, gas, and oil...plus the current state of the economy............the light at the end of the tunnel, has been turned off.

  • #2
    Re: Exhaust manifold repair

    I have welded them. You stop drill the crack ends ,skip weld with Ni rod to keep heat DOWN. Post cool in sand,oven, or Kitty litter. They have cast iron Mig wire ,also.
    Can I ask what the cost was ?
    I can build anything You want , if you draw a picture of it , on the back of a big enough check .

    Comment


    • #3
      Re: Exhaust manifold repair

      Very nice job!

      I am impressed with your talent/welding skills. I've never tried it, though my Dad finished his career as a "steam fitter".

      When I worked for Ingersoll-Rand, we went through a period shortly after we shut down our local foundry, where we "fabricated" almost every component that we used to cast in our foundry. At the time we hired a number of designers and welders and created a "fabrication" department. Your manifold is very much akin to that... and every bit as nice as some of that stuff.

      Great job,

      CWS

      Comment


      • #4
        Re: Exhaust manifold repair

        I do not realy know the cost, as I have not got the bill,

        but the steel used, was
        1/4" x 4" Flat, about 36" long,
        3" x 3" tube, 3/16" tube about 32" long,
        and
        1 3/4" x 1 3/4" tube, about 30" of it,

        an abrasive blade, or most of one,
        about 5 pounds of welding rod,
        and about 15 hrs of my time,

        I had a old head that I bolted things to and built it up on the head.

        besides my time I am sure the cost of it is under $50,
        Push sticks/blocks Save Fingers
        ~~~~~~~~~~~~~~~~~~~
        "The true measure of a man is how he treats someone who can do him absolutely no good."
        attributed to Samuel Johnson
        ~~~~~~~~~~~~~~~~~~~
        PUBLIC NOTICE: Due to recent budget cuts, the rising cost of electricity, gas, and oil...plus the current state of the economy............the light at the end of the tunnel, has been turned off.

        Comment


        • #5
          Re: Exhaust manifold repair

          I had the gasket and used that to transfer the holes to the flat that bolts to the head, using a transfer punch, marked the hole and then drilled out the 3/8" holes, to transfer the larger holes I used a fender washer and then used the transfer punch to mark the hole, I Had also spray painted the flat with gasket over it to help keep in in line, I drilled the large holes first with the 3/8" and then with 1 1/2" drill bit,

          once I had that flat made I figure out the clearances and what I had to do for the tubes coming off the the mounting plate, and started on then, when done with them I mounted the larger tube on them, cutting holes for each one, in the tube with a cold cut blade in a skil type saw, and with the grinder with a cut off blade, when that was done I went back and worked on the unit that had the intake manifold heater on it, and figured it out and bolted it all up and tack welded it in place, (using the gasket for template for the mounting plate to the intake manifold,
          for looks and clearance I tapered the main tube cutting out the excess with the cold cut blade, when that was all done I made the top plate where the cast elbow bolts on, and used the elbow for the the template there, (could not find the proper size of hole saw for the hole so I did torch cut that one out on both the top tube and the plate, drilled and taped the holes for studs, when it was said and done there was very little warpage in it, I am sure that when it runs for a few Hrs, it will relive it self of any stresses,

          I got it bolted on and it all clears and every thing matched up nicely,
          Push sticks/blocks Save Fingers
          ~~~~~~~~~~~~~~~~~~~
          "The true measure of a man is how he treats someone who can do him absolutely no good."
          attributed to Samuel Johnson
          ~~~~~~~~~~~~~~~~~~~
          PUBLIC NOTICE: Due to recent budget cuts, the rising cost of electricity, gas, and oil...plus the current state of the economy............the light at the end of the tunnel, has been turned off.

          Comment


          • #6
            Re: Exhaust manifold repair

            incredible job barry 15 hours is fast for a design build project. very very impressed. now all you need is to harvest the hay

            did you ever think of brazing the old one to cut down on the cracking?

            very nice job.

            rick.
            phoebe it is

            Comment


            • #7
              Re: Exhaust manifold repair

              I did not have a good way of pre heating the cast manifold, is why I went looking for some one more set up, (the BBQ grill we had blew across the yard and was not worth much and was junked), and it would have been minimal in length for this manifold, IF I could have got it up to 300 to 400 degrees, the entire thing I think I could have possibly welded it, but there are basically three type of cast irons on manifolds, (from what I read) and two of the types are very hard to weld, and one type is reasonable easy, I guess some say that there is a power spray that is flame applied that can work fairly well,Stoody 122-11-100 Hot Process Metal Spray Powder Torch Kit but by the time the first guy messed it up, I figured this was the best way to proceed, was to fab my own.



              may be my next project will be some type of oven to heat things like this,
              Push sticks/blocks Save Fingers
              ~~~~~~~~~~~~~~~~~~~
              "The true measure of a man is how he treats someone who can do him absolutely no good."
              attributed to Samuel Johnson
              ~~~~~~~~~~~~~~~~~~~
              PUBLIC NOTICE: Due to recent budget cuts, the rising cost of electricity, gas, and oil...plus the current state of the economy............the light at the end of the tunnel, has been turned off.

              Comment


              • #8
                Re: Exhaust manifold repair

                An excellent example of creativity, craftsmanship, and good old American self reliance.

                Comment


                • #9
                  Re: Exhaust manifold repair

                  Mostly exhaust manifolds are made of low quality cast iron. Some welding attempts may not work on them, but if you buy a new one, glass bead and clean thoroughly. Avoid high temperature paint to last over a month. Old better quality engine blocks occasionally can be saved by a highly trained welding specialist.
                  metal identification tags

                  Comment


                  • #10
                    Re: Exhaust manifold repair

                    WOW!!!!!

                    Comment

                    Working...
                    X