Re: welding Super M exhaust manifold

Posted by george md on November 20, 2004 at 11:37:09 from (65.216.222.101):

In Reply to: Re: welding Super M exhaust manifold posted by gusc on November 19, 2004 at 23:21:15:

gusc,
Thank you very much for the compliments.
After a day of fixing everybodies disasters ,it's
somewhat relaxing to settle down and do some mani-
fold repair (always do it late nite after the
phones quit).
Studs are usually not real hard ,a HS steel
end mill will cut most, once in a while you may
need a carbide cutter. If the mill is near tap
drill size and you center well , the only thing left
in the hole is the thread and they will come out
like a heli-coil. Taking out broken studs and bolts
isn't too bad , but when some clown tries to do
it and breaks a drill in the hole then breaks an
easy out (really called hard outs )in the hole
on top of the drill, then the fun begins. That's
when I wish I had an EDM machine.

Oxy/acet cast iron is the best repair for cast
followed by brazing and the absolute worst choice
is arc welding. Any arc rod that will weld cast
iron will have a hi- nickle content , nickle is
about twice the tensil strength of cast and most
important it has a much greater rate of expansion
and contraction than cast . Cast is not ductile
and can not give a little as the weld cools and
that when the cracks start.It doesn't matter how
many chipping hammers you wear out peening the
arc weld bead , when you start the engine the
manifold and weld change size again and do it
every time you start and stop.Eventually the
weld pulls away from the base material. For
manifolds heat a large section or all to a dull
red before welding , use reasonable amount of
flux with the cast iron rod and maintain heat
for a while after welding.

Below is a link to how to weld cast , there
are several pages , read all of them.

george

• cast iron welding

Follow Ups:

• Re: welding Super M exhaust manifold gusc 21:15:14 11/21/04 (1)
  • Re: welding Super M exhaust manifold george md 21:13:02 11/22/04 (0)

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