How To Repair Manifold Crack
Michael Thomas, Salmon, Idaho: “Because turbochargers rely on exhaust pressure, leaks between the turbo unit and the exhaust manifold can reduce the performance of a turbocharged engine. It’s not uncommon for the heat generated by the high demands of a farm truck or machine to crack the cast iron exhaust manifold. In the past, welding cast iron was a job for experts but today, with the advent of rods such as Muggy Weld 72, electrode average-skill welders can tackle the job. Here’s how I recently repaired a manifold crack.
“Remove the manifold and clean off all oil and dirt. Prep the weld by grinding out the crack 1/2 to 3/4 of the way through the material and drill the ends of the crack in order to prevent the crack from continuing to run after welding. Preheat the cast iron with a torch or forge to a dull red. Weld 1 in. at a time using short arcs with low heat to avoid overheating the cast iron.
“If your bead is blobbing, you need more heat. If the weld is undercutting the cast, you’re using too much heat. Maintain preheat between beads. This is easier with a helper holding the torch. If cracking occurs during cooldown, weld over the first bead with Muggy Weld 77 or similar rod. After the weld is complete it’s important to allow the cast iron to cool slowly. One method is to bury the manifold in sand or cat litter overnight
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How To Repair Manifold Crack ENGINES Michael Thomas Salmon Idaho: “Because turbochargers rely on exhaust pressure leaks between the turbo unit and the exhaust manifold can reduce the performance of a turbocharged engine It’s not uncommon for the heat generated by the high demands of a farm truck or machine to crack the cast iron exhaust manifold In the past welding cast iron was a job for experts but today with the advent of rods such as Muggy Weld 72 electrode average-skill welders can tackle the job Here’s how I recently repaired a manifold crack “Remove the manifold and clean off all oil and dirt Prep the weld by grinding out the crack 1/2 to 3/4 of the way through the material and drill the ends of the crack in order to prevent the crack from continuing to run after welding Preheat the cast iron with a torch or forge to a dull red Weld 1 in at a time using short arcs with low heat to avoid overheating the cast iron “If your bead is blobbing you need more heat If the weld is undercutting the cast you’re using too much heat Maintain preheat between beads This is easier with a helper holding the torch If cracking occurs during cooldown weld over the first bead with Muggy Weld 77 or similar rod After the weld is complete it’s important to allow the cast iron to cool slowly One method is to bury the manifold in sand or cat litter overnight
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