im still a newb welder, and i dont practice that often. I still attempted to make my own splog manifold. Everything was kinda okay after making A LOT of mistakes during the building process (which i expected from my first manifold) Since the manifold was ugly as ----, I nick-named it "ugly betty" :1

However, after a few days of driving the car (about 40 miles a day...to and from work for 3 days), i leave the car parked as i went on vacation. i come home to find this:







what do you think caused this? Was it the cheap ebay flange? My crappy welding? Too much heat? I'm just looking for some advice so this wont happen again.

thanx.

oh, this was done with a lincoln electric gasless mig. I think its called the weld pack 1200....i got it from home depot a few years ago....but i cant upgrade this one like i originally thoguht

 

that is some crazy *** ---- right there.

 

wow, I don't know what caused it but looking at that mani and the dp in the background.... that setup is hardcore. And I thought my setup got alot of comments about being ghetto

Complex had a flange he welded on yuriy's up-pipe crumble pretty similar. I think I remember they blamed it on the cheapass material from the ebay flange. He welded on a weir flange I had lying around and said the welding difference was night and day. Ask him?

 

Its the cheap ebay flange, i've had a couple do that to me. They are almost sandy inside. They dont like heat at all.

 

that almost looks like a cast flange to me...

cast flanges = fail

 

thats what i thoguht too...since i didnt think metal should leave powder.

anyway, thanx for the help guys. I got a new steel flange from ATP turbo on the way.

 

looks like it was made from chocolat :P

 

lol

Maybe they made it with powder and a press. Like the way pills are made.

 

good thing you caught that before any ---- got down into the turbo.

 

How badly was it warped after you welded it on? You should check this with something straight after welding.

I agree the flange lookes like it might have been made from compressed dogshit, and that is probably the major issue, but also keep in mind that a warped flange will be stressed quite a bit (and also stresses the turbine housing quite a bit).

I have seen turbine housings actually break from being bolted to a warped flange.

Try to check it for flatness after welding next time (a steel ruler is good), and use a 60 grit flapdisc on a 4.5" grinder to (carefully) level it out a bit if necessary. Or even a large file will work although it's a little slow.