I have a big nasty crack on my manifold and I dont have the $$$$ to buy a nice replacement.

Can you weld this up with a Mig? The crack appears at the area highlighed in this image (http://www.users.qwest.net/~chrismeyer/jeep/pics/exhaust.jpg).

Any help would be appricated! Thanks!

Chris
:usa:

Yep. You can weld it. Just dont burn a hole in the damn thing.

weld away! most TJ's that get wheeled hard have done this. at least yours is easy to get to.

i have cracked three seperate ones on my yj over the years, and some how end up with free replacement ones. but i did weld the first one up. welding on cast iron isn't really all that great, (i'm not a welding guru, you just make sure you lay on enough wire so no exhaust can get out) its not a permenant solution, you will just keep cracking the thing on down the road.

you would think i would just break down and go buy a quality header but since i still haven't spent any money out of my pocket, eh.

i think that driving through icy cold water has done it every time to me. the cold water hits the hot metal and CRACK!! i never noticed the exact timing of when they went, but it was always around deep water crossings at places like hackett gulch in the winter.

What year Jeep? If you've got less than 50,000 miles on it the dealership has to replace it free of charge, even if you're not the original owner. I got one free a few years ago.

what they said. weldin on manifolds is pretty simple...make sure your line speed si roughly 20-30% lower than your amperage. its tricky to fix if you burn through, but you just have to lay down a bunch of small beads of wire, and once you fill the hole go back over it....always remembering to move the gun around quickly.... BTW dont buy a throley header if you ever need one. a friend had one for 18 months and it was cracked to shit. takin them 4-6 weeks to make him a new one. they use to make em and quit becasue they were cracking so bad.
thats the manifold i welded on.
Hunter

Originally posted by withamc
What year Jeep? If you've got less than 50,000 miles on it the dealership has to replace it free of charge, even if you're not the original owner. I got one free a few years ago.

Its a 94 with over 104K miles on it... Im guessing no dice at the dealership.

Mine is also cracked right now. I plan on Miging it. Though I suspect Braze would also work

I'm still relatively new to this welding thing and was wondering if it has to be MIG welded?

I have the Licoln Weld Pak 155 with .035 flux core wire. I'm assuming that would work just as well. Let me know if not.

Thanks in advance!

That should work fine
Just keep the heat down and DONT burn through.

In fact find a couple pieces of scrap exaust pipe and lay a couple practice beads first just to be safe

I welded mine up a little over 4 months ago and have had no problems. I tried brazing it first but that cracked again, I probable just fawked it up thou...

Originally posted by XJ Hunter
BTW dont buy a throley header if you ever need one. a friend had one for 18 months and it was cracked to shit. takin them 4-6 weeks to make him a new one. they use to make em and quit becasue they were cracking so bad.
thats the manifold i welded on.
Hunter

Are you talking header or manifold? If you're talking about Thorley headers, your :smokin: crack. I've owned and run Thorley headers for over 8 years NO PROBLEM and they were the thickest material on the market.

If anything I would ditch the manifold set up all the way and get a set of headers, they make way too many CA smog leagal ones now not to.

Your wasting TIME!

Me and ALOT of my buddies tried welding them.. and they all cracked again...My frined that works for JEEP also said its a waste of time...

Spend the $$$ and get a BORLA... had it on 3 4.0's in the past and on my current Jeep.. they are great... and fit perfect..

Your gonna get:mad2: if you weld it..Plus your gonna burn up gas milege if its you daily driver if you dont fix it..just

Milkman..
Just my .02$

:nuke: the factory manifold!

welded mine over a year ago and i have no new cracks. Mine is a 94 4.moved my o2 sensor into the header from the exhaust pipe at the same time and it works just fine.

I welded Mine in the same spot. Held up for 3 years before it cracked in a different spot. I arc welded mine. Many of my friends migged theirs only to have them crack at or near the weld a month or so later.
http://community.webshots.com/storage/1/v4/9/87/5/27298705kroIVrtIpa_ph.jpg
http://community.webshots.com/storage/1/v2/9/87/58/27298758MEkfPSZqyv_ph.jpg
If the crack is inaccesable like mine was (insert your own joke here) you'll have to wed the tubes together.

http://community.webshots.com/storage/1/v2/9/87/58/27298758MEkfPSZqyv_ph.jpg

welp, welded it up last weekend, and it seems to be holding fine! Ill let you know if it breaks however.

Chris

Is this Cast or steel