Grind it, Drill it, Weld it, F it?

[HiSPL]

I got this 90+ manifold. I bought it cheap knowing it had this crack, and repair.

It's been welded up (I think poorly, but I'm no pro) but the crack has propagated to the inside.

https://imgur.com/dIrldXl

https://imgur.com/Cepxrj8

https://imgur.com/thorhkX

So. What are the thoughts here? Do I drill the ends of the internal crack and rock it? Do I weld up the internal crack? Do I grind off the old fix and redo it completely?


What are your thoughts?

 

[StanleyR]

F it and buy a Kia

 

[Led]

Grind it down, drill the ends, reweld.

Or, run the damn thing and don’t worry about it. Once it gets hot it’ll close up.

 

[fatcatbestcat]

F it?

Wear a condom, my brother in Christ

 

[Jack]

Idk about these guys
.. chances are it’s fine. I would run it. Next time heat the entire manifold prior to welding it up. It helps


But just run it

 

[HiSPL]

I think I'll at least grind the current weld back. It's like 1/4" proud of the surface. I'll look at the porosity and see what we see. If it looks solid I'll just run it as-is. I don't want to weld cast iron.

 

[Jack]

I think I'll at least grind the current weld back. It's like 1/4" proud of the surface. I'll look at the porosity and see what we see. If it looks solid I'll just run it as-is. I don't want to weld cast iron.

It’s cast steel


Edit no it’s cast iron
Just put it in the oven at 450 right before welding or torch it

 

[Led]

A crack like that would take a braze repair really well.

 

[240 240]

It’s cast steel


Edit no it’s cast iron
Just put it in the oven at 450 right before welding or torch it

how many minutes?
Baking instructions are a serious matter

 

[Jack]

how many minutes?
Baking instructions are a serious matter

Until it reaches temp

 

[threewagons]

A crack like that would take a braze repair really well.

I mig brazed my cracks with ERCuSi-A after drilling the ends, beveling, and preheating.

Cracked again in no time, unfortunately. Maybe there's a better alloy but silicon bronze didn't work for me.

 

[HiSPL]

The part that bothers me the most is the fact that whoever welded it, didn’t drill the ends.

I’m afraid I’m gonna have to clean this up and redo it all. Probably have to stick weld it to get the penetration. I’ve got a horror fraught multi process machine. Not sure the tig has enough ass on it to do this job.

 

[Sjeng]

Drill out ends and grind out all weld material/crack.
Pre heat to approx 300C.
Easiest is MMA, use high nickel content electrodes.
This material has a similar coefficient of expansion as cast iron, so residual stress from the welding is greatly reduced.

https://esab.com/us/nam_en/products-solutions/product/filler-metals/nickel/stick-electrodes-smaw/ok-nife-ci-a/

You might peen the weld area after welding.
Then gradually cool the part down.
The best is using a cool down oven, but packing the part in glass wool also might work.

Mig welding with ER70 or similar is a bad idea, almost certain to crack again.

 

[white855T]

The part that bothers me the most is the fact that whoever welded it, didn’t drill the ends.

I’m afraid I’m gonna have to clean this up and redo it all. Probably have to stick weld it to get the penetration. I’ve got a horror fraught multi process machine. Not sure the tig has enough ass on it to do this job.

When I get them repaired, tig is used. You just have to know how to do it. You can do it with mig but you need the correct nickle wire to do it. Doing it mig, you definitely want it hot enough to penetrate. But sometimes the material will burn off too fast if it's really cooked.

 

[122power]

Heat it up like he said, do your weld work.

You need to cool cast iron slow. So put that in a bucket / container of sand so it cools slow and even to prevent it from cracking further.