Exhaust Manifold Repair in pictures
Discussion
One of my exhaust manifolds I knew had a crack in it, but I thought that was all that was wrong with it.
However on closer examination one of the other tubes had a long crack in it, right up against one of the other tubes.
This is the best photo I could get of it, it doesn't show up very well.
After pondering for a while what to do, I decided I may as well have a go at fixing it.
I was going to have to remove one of the manifold tubes, then weld it back in, this is how I did it.
I am no expert welder, that will probably be obvious shortly!
I worked out that I was going to have to do something clever so I cut the tube like this, then I could weld the tube back in half way round from the inside, then replace the triangular bit and weld it from the outside.
I drilled the hole so I could cut it using a jigsaw.
Here's the triangular bit removed, then I drilled some small holes and used a hacksaw blade to cut the tube further.
Finally I managed to get it free enough so pulling it gently backwards and forwards eventually broke the metal away.
I also cut the tube further along where I could get to it to weld it all the way round from the outside.
Once the tube was removed the crack was revealed.
Close up
I then welded up the crack (I ran a jigsaw down it to clean it up first).
As I said I am no expert welder but its better than it was!
Then it was just a case of welding it back together!
Fortunately the welds on the manifolds are underneath, so very little of it will be visible.
Chris
However on closer examination one of the other tubes had a long crack in it, right up against one of the other tubes.
This is the best photo I could get of it, it doesn't show up very well.
After pondering for a while what to do, I decided I may as well have a go at fixing it.
I was going to have to remove one of the manifold tubes, then weld it back in, this is how I did it.
I am no expert welder, that will probably be obvious shortly!
I worked out that I was going to have to do something clever so I cut the tube like this, then I could weld the tube back in half way round from the inside, then replace the triangular bit and weld it from the outside.
I drilled the hole so I could cut it using a jigsaw.
Here's the triangular bit removed, then I drilled some small holes and used a hacksaw blade to cut the tube further.
Finally I managed to get it free enough so pulling it gently backwards and forwards eventually broke the metal away.
I also cut the tube further along where I could get to it to weld it all the way round from the outside.
Once the tube was removed the crack was revealed.
Close up
I then welded up the crack (I ran a jigsaw down it to clean it up first).
As I said I am no expert welder but its better than it was!
Then it was just a case of welding it back together!
Fortunately the welds on the manifolds are underneath, so very little of it will be visible.
Chris
Edited by Barkychoc on Wednesday 7th May 19:04
Gerald-TVR said:
I'd have just got a new one - well impressed
Have you seen what they cost new! 
You could buy a welder and all the kit for less than a new manifold!
Only kidding obviously a new one is better, but I was in tightarse mode, and as it was buggered I figured I had nothing to lose if I screwed it up - if I made a complete hash of it I'd just have to buy one.
respect ! what a superb job. 
Chris
Good to see you back working on the car again. Great job on the exhaust - I'm sure one of mine has been leaking for a while (annoying ticking under load and uncool popping and banging getting worse). Haven't been able to track down where it's leaking from as yet but that's confirmed that I'll just have to get the manifold off and take a look.
Steve
Good to see you back working on the car again. Great job on the exhaust - I'm sure one of mine has been leaking for a while (annoying ticking under load and uncool popping and banging getting worse). Haven't been able to track down where it's leaking from as yet but that's confirmed that I'll just have to get the manifold off and take a look.
Steve
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