SpankedYA!

We have gone over it somewhere in the post. THe crack doesn't seem to be leaking exhaust when its running and heated up.

gon3r

i'd like to see pics of the edges of all the flanges to make sure it wasn't dropped. i'd also like to know what type of filler material was used for the welds. 2 possibilities?

daubleaaron

I tried to get good pics of the edges of the flanges for you weir.

http://img.villagephotos.com/p/2005-2/957082/1.JPG
http://img.villagephotos.com/p/2005-2/957082/6.JPG
http://img.villagephotos.com/p/2005-2/957082/2.JPG
http://img.villagephotos.com/p/2005-2/957082/3.JPG
http://img.villagephotos.com/p/2005-2/957082/4.JPG
http://img.villagephotos.com/p/2005-2/957082/5.JPG

88dx

looks like you had a leak at the manifold to T3 flange

Jays91DXhatch

And from that picture, looks like not enough filler in that weld..don't think it's supposed to be like that.

rudebwoy

but the welds did not crack the ss steel cracked. so its not a welding issue

myshtern

They usually dont. The filler adds properties which actually make the weld stronger than the steel it's on. However because the surroundings were super heated when welding, it could make them brittle. I'm not saying thats what happened, here just FYI.

gon3r

doesn't look dropped to me. the welds look a little undercut, but as rude mentioned, the steel around them will be more brittle than the weld itself. must have used too much heat when welding?

SpankedYA!

It was 308L rod. When I made that I was welding at a very high amp. Around 165. From practice and experience I have since lowered amperage considerably. It is all a learning process. Through all my manifold sales I have always been up front to tell people I am a HOBBY welder. I am not a welder by trade. Keep in mind that Aaron paid $175 SHIPPED for this. I was not out to make lots of money. It was more hobby and some money to help out with bills. Do the math. After materials, filler rod, argon, electricity, and many hours, how much money did I make? My new stuff is light years ahead of my first stuff and the prices are about the same. I only make 1 to 2 manifolds a month now. I started a little website but realized I don't care to make a job out of it and will be closing the site at the end of the month. Like I stated earlier I will make a new one free of charge for Aaron and he has requested changes in design and an exteranl wastegate that I do at no charge to him. I made this post not trying to hide mistake but to honestly find out problems in my process and or design.

hcivic

okay after those second sets of photo's it looks like you made more than 1 pass and or ran filled a larg gap? but those craks did start at the edge of the bead and move forward. YOu were right to think it was the heat you welded at. The metal got too hot and became fragile and craked. Like you said you do this a s a hobby and you have improved 50x scince that time so build the new one and move one. Bottom line is your manifolds work good and cost less than the pros and you are doing a free replacement. The fact your making changes for free is a big testement to your busns morals.