4 Days is all it took

[hollowpockets]

I have a history of bad luck with cars and this new M400 has only managed 4 days before deciding to upset me, went for a wee run on saturday to show my brother the new car and it would appear the exhaust manifold has cracked at the turbo end just around the weld at the flange, is it easy enough to remove and have one of the fitters at my work weld it, or should i just replace it? has anyone welded in an extra support to stop this from re-occuring?

Thanks again

Graham

[Adrian W]

hollowpockets said:

I have a history of bad luck with cars and this new M400 has only managed 4 days before deciding to upset me, went for a wee run on saturday to show my brother the new car and it would appear the exhaust manifold has cracked at the turbo end just around the weld at the flange, is it easy enough to remove and have one of the fitters at my work weld it, or should i just replace it? has anyone welded in an extra support to stop this from re-occuring?

Thanks again

Graham

Weld it up, theyre made of chocolate, problem is the turbo's are hung off them with very little support, so only a matter of time!

[NobleGuy]

Does seem a bit wierd that they aren't supported a bit better.
Is it the rear turbo (easier to get to) or front?

[S26VE P]

Reweld with supports.

[hollowpockets]

NobleGuy said:

Does seem a bit wierd that they aren't supported a bit better.
Is it the rear turbo (easier to get to) or front?

Its the rear one, Im staying late at work tonight, got all the tools and a workshop to do it in and got a few very experienced welders to assist, hopefully have it back on the road by wednesday.

Im assuming i just need to remove the black box that the intercooler is housed in and the metal heat shield to access the manifold? any other advice before i start and mess it up?

[gadgeroonie]

West tuning do a nice replacement

with a gusset welded over the area's that are prone to crack

[mgbond]

Or get a roush fitted, don't they sort this issue out?

Bondy

[s,one]

I managed the same job myself a couple of weeks ago. Some of the bolts are bloody awkward as you's expect, you will need to undo the the turbo and lay it to one side carefully while still conected.
Not difficult but lots of screws on the intercooler which is a pain and if your like me and put it all back together and realise you havent put the heat shiled back on above the manifold you will be a bit pissed as I was.
All up took me about 5 hours but my ability with the spanners is very limited.

steve

[Adrian W]

mgbond said:

Or get a roush fitted, don't they sort this issue out?

Bondy

No, fundamentally the problem is the positioning of the turbo, it should have been further away from the engine, there wouldnt have been a noticable increase in lag, they could have been put in the airflow and some sort of proper support could have been engineered.

You hold a turbo at arms length and feel what i'm talking about (if you can)

[mgbond]

Adrian W said:

mgbond said:

Or get a roush fitted, don't they sort this issue out?

Bondy

No, fundamentally the problem is the positioning of the turbo, it should have been further away from the engine, there wouldnt have been a noticable increase in lag, they could have been put in the airflow and some sort of proper support could have been engineered.

You hold a turbo at arms length and feel what i'm talking about (if you can)

Just realised, I was refering to the exhaust bracket that breaks. Different issue, sorry

Bondy

[hollowpockets]

[quote=s,one]I managed the same job myself a couple of weeks ago. Some of the bolts are bloody awkward as you's expect, you will need to undo the the turbo and lay it to one side carefully while still conected.
Not difficult but lots of screws on the intercooler which is a pain and if your like me and put it all back together and realise you havent put the heat shiled back on above the manifold you will be a bit pissed as I was.
All up took me about 5 hours but my ability with the spanners is very limited.

steve
[/quote]

Right so my final question is what type of welding is required, im assuming the manifold is stainless steel, can someone confirm this?

[S26VE P]

depends what welders you got but i personally would tig weld it. But sure mig would suffice. not 100% on the material. not had the pleasure of doing mine yet.

[s,one]

hollowpockets said:

[quote=s,one]I managed the same job myself a couple of weeks ago. Some of the bolts are bloody awkward as you's expect, you will need to undo the the turbo and lay it to one side carefully while still conected.
Not difficult but lots of screws on the intercooler which is a pain and if your like me and put it all back together and realise you havent put the heat shiled back on above the manifold you will be a bit pissed as I was.
All up took me about 5 hours but my ability with the spanners is very limited.

steve

Right so my final question is what type of welding is required, im assuming the manifold is stainless steel, can someone confirm this?

I did mine with mig but tig is better.

[Ash 996 GT2]

mgbond said:

Or get a roush fitted, don't they sort this issue out?

Bondy

Yes, it does, that is what I did, I got fed up of the chocolate bracket breaking all the time so took it to Trevor, twas the first M400 to be done.

Wow, what a difference it made.

Soooo much more power

[Adrian W]

Ash we're talking about the manifold

[s,one]

Should I ask how much the Roush system is?

[S26VE P]

IIRC around 3k. fitted mapped etc etc.

[Ash 996 GT2]

Adrian W said:

Ash we're talking about the manifold

I know, maybe I should have made myself clear.

Once you have fixed the manifold, put a Roush on, it will not break again

Better?

How are you, not seen you since the event, are you coming to the Britcar 24 to support us?

[hollowpockets]

Ash 996 GT2 said:

Adrian W said:

Ash we're talking about the manifold

I know, maybe I should have made myself clear.

Once you have fixed the manifold, put a Roush on, it will not break again

Better?

How are you, not seen you since the event, are you coming to the Britcar 24 to support us?

Well my car has the Roush and the manifold just broke in two, looks like the bot supporting it had come completely loose, its being welded today by a local specialist though so hopefully back on the road tonight, took two hours to remove.

[Adrian W]

Ash 996 GT2 said:

Adrian W said:

Ash we're talking about the manifold

I know, maybe I should have made myself clear.

Once you have fixed the manifold, put a Roush on, it will not break again

Better?

How are you, not seen you since the event, are you coming to the Britcar 24 to support us?

would be good, what date is it?