Exhaust gasket failure

[TuxMan]

I've been at Silverstone today and something did not feel right with the car , coupled to that a bad neck and I decided to leave early , car felt ok on way home but I had a nagging doubt something was wrong .
Closer inspection when I got home revealed this :



So couple of hours later I found the exhaust to turbo gasket had failed , lots of very hot gases flowing where it should not !!!! Caused quite a bit of damage






Also completely wreaked the bottom of my new carbon intercooler box !!!!!



Guess another busy week ahead .

Tux

[mgbond]

Could this be over run fuel exploding in the exhaust as I know you get flames. Recently as one of my banks is very rich, it took out the manifold to head gasket?

[5paulmv]

Been very lucky with this one Simon guessing a manifold bolt had come loose

[Mike Tuckwood]

Cheap gaskets. :-o
Stick to proper steel gaskets and this type of failure is far less likely to occurr.

My Impreza was running competitively in Time Attack, at Dono about 7 or 8 years ago and I had a similar exhaust Gasket Failure, that melted the speedo sensor off my gearbox, all the wiring etc.


Mike.

[Metalman]

Simon, did you use the decent Nissan gaskets? I've always used these and not had a problem.

[verba1]

sorry to see that mate hope you get it sorted !

[TuxMan]

As Mike suggested gasket failure due to them being crap !!! Nuts were tight just gasket that failed , noticed mixture had gone rich on that exhaust bank guess through the blown gasket and the lambda getting incorrect readings .
New Nissan gaskets to be fitted this week , already have them on the inlet side .
Tux

[GC1]

Get your tool's out.....

[RobP]

I don't use gaskets on turbo-exhaust junction...

[Mike Tuckwood]

You'll need to get both machined faces checked accurately Simon. The enormous and concentrated heat and gas flow they see when this happens can cause deformations which lead to an almost identical failure when "repaired", that then casts doubt on the original cause of the failure and gets rather confusing too. :-)


If there are issues requiring surfaces to be skimmed, you'll have "fun" getting them machined as most machine shops have trouble clamping complex shapes well enough to machine them. I hope it's recoverable and not too much engineering level damage has been done.


Mike.

[TuxMan]

Have checked exhaust flange and its thankfully nice and flat , put the 2 surfaces back together without gasket and they look nice and flat !!! Hopefully just a rebuild with metal gaskets will sort it , going to fit new oil and water lines as well as they are damaged as well .
Good job I came home early , dread to think what would have happend if a ad carried on all afternoon !!!!!!!

[2.5bluenob]

Simon do you use the cheap looking gaskets they supply with the turbos? as i always chuck them straight into the bin. The Nissan ones are much better quality in my eyes.

Steve

[Slider21]

Someone said bad things happen in threes on Saturday, can't blame me this time I was decorating,at least you left early or god knows what could have happened.

Neil.

[Juno]

I came along to your garage to have a chat but Melindi said you had gone home with broken body, must be those new brakes. Just as well as that could have been nasty if you kept going :-(

[Gadgeroonie]

have to admire you dedication to track days

how many times has it been on track now ?

i reckon you should join time attack - its like a track day but competitive lap times

[TuxMan]

Hi Barry , sorry i missed you , probably a good job i left early !!

5 days so far Gadge , plenty more to come


All new bits ordered , hopefully be back on the road over the weekend although ive got to change front turbo gasket which is a pain !!!!!

Tux

[RobP]

TuxMan said:

Hi Barry , sorry i missed you , probably a good job i left early !!

5 days so far Gadge , plenty more to come

Tux

Dear, oh dear, Tux - only 5
I wasn't kidding when I said I do not use gaskets there. As recommended by Ford
WRC Team. And no issues in 7 yrs of tracking this car.

[Juno]

TuxMan said:

Hi Barry , sorry i missed you , probably a good job i left early !!

5 days so far Gadge , plenty more to come


All new bits ordered , hopefully be back on the road over the weekend although ive got to change front turbo gasket which is a pain !!!!!

Tux

Next Time :-)

[Rob_W]

Do you think having the turbo blankets/covers actually puts more stress on the system (gaskets etc) by keeping more of the heat in?

[TuxMan]

Hi RobP , put the surfaces together tonite and they do fit very well , but not airtight , with the engine running I can feel a small amount of air seeping out .

Rob w , no idea mate , but I'm guessing persistently revving to 7850 and lots of track work found a weakness !!!!!
The front turbo does not have a blanket fitted so I will check the condition of the gasket when I get it apart .

Tux

Tux