crack in lower manifold

[jonny tvr]

I've got a crack in the lower part of my manifold (where it joins the exhaust). I don't want to weld as I've done this before and it hasn't lasted. However I don't want to buy a new manifold. I was thinking about having the cracked section taken out (sawing it out) and a new section put in and therefore joining the manifold and exhaust. Has anyone sone this?

[olly]

Isn't that a lot more work, and your still toing to have 2 new welds that can break/crack ? I don't know if putting a plate over the crack is an option ?

[satman]

Also, joints tend to be there for a reason...such as one section needing to be 'twisted' into place to meet another section or the head for example. Removing a joint may not make this a possiblity if you have to change something later...

[Julian64]

The weld should actually be stronger than the existing material.

Be careful who you're using for your welding. Remember slow heating and cooling of a weld is actually softening the material, rapid cooling is actually tempering.

Much more control over this with gas rather than electric, but electric is usually the cheapest option for a garage.