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Old 17-07-2017, 18:55   #1
adamfitz
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manifold cracks

picked up a turbo kit last week due to having a crack in my current manifold and it wasnt able to be welded.
whipped off the turbo earlier and came across these small cracks/splits in and around the flange area. they havent broken through but i dont want to fit this for the cracks to then grow and im back to square one and £1500 lighter for nothing!
any thoughts or opinions?

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Last edited by adamfitz; 17-07-2017 at 18:57..
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Old 18-07-2017, 16:18   #2
adamfitz
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anyone any thoughts?
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Old 18-07-2017, 16:33   #3
gary evo7
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Personaly myself wouldnt use it would go in the bin.
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Old 18-07-2017, 16:42   #4
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It would probably work fine for a while but there are quite a few cracks there and I'd be more worried about bits falling off and causing some real damage
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Old 18-07-2017, 16:49   #5
adamfitz
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looks like its going back to the seller then!
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Old 19-07-2017, 20:44   #6
Scottpayne
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I see these cracks often on heavy Diesel engine that I work on. More so caused by high heat and heavy strain when pulling. Once they crack it's just your luck what happens next you can run them for long enough and they won't get any worse. How ever they can expand more distort the flange and break up which I have also saw happen after it chewed a turbo and also the secondary turbo. So buddy get it off and sent back.
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Old 19-07-2017, 20:44   #7
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Heavy diesel ( engines )
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Old 19-07-2017, 21:05   #8
adamfitz
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Quote:
Originally Posted by Scottpayne View Post
I see these cracks often on heavy Diesel engine that I work on. More so caused by high heat and heavy strain when pulling. Once they crack it's just your luck what happens next you can run them for long enough and they won't get any worse. How ever they can expand more distort the flange and break up which I have also saw happen after it chewed a turbo and also the secondary turbo. So buddy get it off and sent back.
cheers mate, im dubious as to what to do. ive spoken to the seller and he was going to investigate it with the guy he purchased from to see what kind of life it had, as he tells me he never fitted it or split the turbo from manifold. last thing i need is fit it then it lunches the turbo after a week and im even more out of pocket
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Old 20-07-2017, 05:11   #9
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Go see a engineer with a tig welder and see if he is can put a bead of weld over the cracks and then you might have to get the flange skimmed sanded flat.
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Old 20-07-2017, 05:21   #10
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very hard to do so as the metal is contaminated from exhaust particles. Since it is probably stainless, the repair will be marginal at best..
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Old 20-07-2017, 05:47   #11
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I'll put it this way, I can fix that, and it will last longer than it has lasted up to now.


I'll give you a hint of the process:


Firstly you need a grinder, you need to fine grind the external part ( the outside part of the flange as you have it sit on a table i.e in the way it sits on the head) slightly, then use some 180 grit sand paper on it, and re-weld the flange on the outside. Then you need to port the collector outlet through the use of carbide stones, by as much as it is allowing you to do so, according to the gasket and exhaust housing inlet flange dimensions. After you do that, you need to use again carbide stone and scuff the parts where the cracks are, until the cracks are no more, then you need to fill that up with welding. The flange will then need to be resurfaced.



Another way is to cut the flange clean off the headers, and make a brand new one and weld it back on. Again there is a certain process to clean the weld to be surfaces before welding.









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Last edited by 4g638; 20-07-2017 at 05:52.. Reason: typo
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Old 20-07-2017, 09:18   #12
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Why would the op pay to have it repaired when he has already bought the
item thinking they were it usable condition ?? ok the seller didn't realise it
has damage but is now aware its not useable. Is it possible to either send
the whole lot back for a refund or a part refund to have it replaced.
For the cost & hassle to have it repaired not knowing if the repair will last.
Is it really worth it ??
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Old 20-07-2017, 10:52   #13
Jabo
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If OP fancies some DIY then why not?

Otherwise send back, what's the point of risking ruining the turbo?
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Old 20-07-2017, 11:31   #14
kevy
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If OP fancies some DIY then why not?

Otherwise send back, what's the point of risking ruining the turbo?
Would you do a diy repair to it when you've just shelled out 1500 quid for it ?? wouldn't be me
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Old 20-07-2017, 11:36   #15
Jabo
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manifold cracks

If I had all the kit and experience in doing so that would probably be the fastest and cheapest option provided I needed to have it fast.

Otherwise return as faulty and not as advertised.
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Last edited by Jabo; 20-07-2017 at 11:42..
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