Welding Cast Iron Exhaust Manifold
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- Опубліковано 16 жов 2024
- Guys, in this video I will attempt weld the cast iron exhaust manifold from my 1988 Jeep YJ wrangler. (Spoiler alert: It worked!) This comes off the 4.2L engine. I initially noticed this crack while doing some carburetor work. I’ve never welded any cast metal before, but after a little research I decided to give it a go myself. I was able to cut and grind out the crack and then weld it all up using my flux core welder. The setup for this welder is: 0.030in flux core MIG wire and I’m running my Lincoln electric 125HD with DC electrode negative. Unfortunately, it doesn’t have the actual settings for the voltage and feed speed. I have the settings for welding 1/4” steel. Hopefully this helps you in a future repair!
I hope you enjoy the video. Please assess your own capabilities before attempting anything you see in this or any other video.
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It's almost impossible to get a new or replacement manifold, so I really need it welded. Your video is valuable to give me some pointers, thank you. There are quite a few slightly different ways people attempt this, so I appreciate you sharing how you did it.
How did it hold up over time?
Thanks for your video bro! Shell do mine soon :) liked and subscribed.
Good video.
Awesome video man. Thank you sincerely.
Glad you enjoyed it!
I am curious if this has held up over the long-term. I've had good luck welding ornamental cast iron with MIG but never tried something like an exhaust manifold.
I’ve beat on it pretty good riding trails. Even with a couple overheating events. So far so good. On the farm I grew up on, we would have our tractor exhaust manifold welded it would last four years. That was stick, if I remember correctly. I’ll update if it fails.
Nice job. You did well. May God Bless
Thanks, not a welder by trade, but I do enjoy it!
They make an arc rod, just for cast. Nickle, works great.
Thanks for the advice. Right now all I have is my flux core welder. I’m planning on getting a stick and TIG in the future. There are plenty of parts on my old Jeep that will break, so having other solutions is great! Once again thanks.
Did it ever crack again?
I had maybe about 100hrs on it before I recently sold it. It hasn’t cracked up to that point.
Thx for the video. Did the weld hold? I have a couple odd jobs including an exhaust manifold crack that I was thinking about getting a welder for. Appreciate hearing if it lasted.
So far it has held with no issue. It’s mainly a mountain trail rig. I have taken it out and ride it tough it hasn’t had any issues so far. I’ll reply if I see it fail.
I was actually interested in knowing what pressure and time you were using and if you it were just a small 3/8" cut/crack would you just touch weld❓
I don’t remember the feed speed or voltage I was using. I’m in the middle of a move and everything is in storage or I’d go and get the swing of the machine I was using. If it was that small I would drill on the start and end of the crack to try to prevent it from spreading. I’d the grind out about 1/16” into the crack to give the weld something to bite into and do kind of like what you are talking. Small welds and making sure to clean the slag off between. That would be my approach.
Swing = settings
Does anyone know if this works with any old flux core? I thought i read that some flux core you can't reweld over, also thought you needed a special kind of rod such as 90% nickel or something for cast iron?
Thanks
I’ve welded cast with just regular flux cord
Is it durable?
I believe I would have removed that O2 sensor first…
Agreed, normally I would. I tried getting it off using every means I knew. I felt it would break off and I’d have to patch a hole. I really doubted the Jeep was reading anything from it, so…I just went with it. Good point for other vehicles.
Heat around the 02 sensor then peen it with an air hammer. She’ll come out.
Really dont understand why they risk Mag welding cast irons in these situations, far better and safer to flame braze weld or even Mig braze weld the part.
FIRST rule of welding cast iron (particularly dirty shit like exhaust elements) - NEVER use a hard-stone grinder of any type. It drags carbon out into the weld area.
Use a file, die grinder, or a Dremel (for little jobs) with a burr cutter, but never a stone of any kind. You did mention flux core but not the actual type of wire. This type of repair requires a nickel type filler. Your incorrect procedure is the reason why you have porosity or inclusions or whatever went wrong.
What settings were you running?
The Lincoln electric unit I had didn’t have “real” settings as a higher end model would have. So I don’t have the voltage, current, or feed rate info. The current setting was on the “B”, so lower current on the selector. Also, the feed rate was about 1/4 off full scale on that selector. That I usually adjust in the feedback I’m getting from the puddle and the wand. I hope this might help to some extent.
@@outdoortypelifestyle9489 rofl it actually does haha,belive it or not I know exactly what you are talking about haha,working with old machines isnt always the worst thing,sincerely appreciate the response thanks bro