Crack!

[Mark Halligan]

Just as I almost have the car ready for some track time the IM goes and splits on me while I am out playing. Nothing dramatic, just a weld giving up under the pressure from the GT35.




My dilemma is, do I just have it re-welded and carry on and hope it doesn't go again or use something else?

I am thinking about the option of using the Wagner IM, at least being cast its strong, but I'll need to mod it to get my 80mm TB to fit onto it.

Does anyone here have a Wagner IM not fitted, so that they can measure the 'hole' where the TB bolts onto it. I need to know if there is enough metal there to open it up and fit a flange for the 80mm TB I have. I'd very much appreciate the info if anyone can help, thanks.

A proper kick in the nuts this is, as I am well skint at the moment.

I still love my GT35 though LOL

Cheers

[Lupo911]

Does anyone here have a Wagner IM not fitted, so that they can measure the 'hole' where the TB bolts onto it. I need to know if there is enough metal there to open it up and fit a flange for the 80mm TB I have. I'd very much appreciate the info if anyone can help, thanks.

Cheers

Hey Mark, just ask me...

the Inside is 65mm, the smalles Diameter on the Outside is 81mm.

I would cut the Flange on the IM, machine a Flange that will fit to you TB and Weld it on.. that will work.

[Rusty]

Nice crack Mark

[Sonic]

Thats a shame!

Im looking at the wagner reverse IM also.. looks like a good route.

[gnutz2]

I know how annoyed you must be, but a very simple solution would be to weld the IM in situ on the car.

It would save you a lot of money and time and only take a good welder a few min's to do, the hardest part would be cleaning the crack well enough to get no contamination in the weld.

Good luck

[s2driveruk]

ouch, sure is a decent crack there......which track and when Mark, not seen your car since the rollers at PTS :shock:

Good luck getting it sorted

[Mark Halligan]

I know how annoyed you must be, but a very simple solution would be to weld the IM in situ on the car.

It would save you a lot of money and time and only take a good welder a few min's to do, the hardest part would be cleaning the crack well enough to get no contamination in the weld.

Good luck

Yep thats my quickest and cheapest option. But I am not sure how future proof it will be.

It's only taken me about about four weeks (since the remap) to break it, and thats only really playing with the thing. I am not sure that it will hold up too well on the track, well maybe with a smaller turbo but not the GT35.

Looks like I might have to switch from the dual plenum welded IM to the single plenum cast IM design to feel confident that it wont go pop again.....

[Mark Halligan]

Hey Mark, just ask me...

the Inside is 65mm, the smalles Diameter on the Outside is 81mm.

I would cut the Flange on the IM, machine a Flange that will fit to you TB and Weld it on.. that will work.

Thanks for the info

[Billman]

you got PM

[Rusty]

You crazy boost hungry man, no such problems with a mere 1.5 bar (no such speed either )

[terrybullwon]

Sorry to see this mark, I have a furans IM here that you can use?

Call me if need be cheers James

[newsh]

Thats a shame Mark. I think the problem with these kind of manifolds is the flat panels, the pressure distorts them, tries to make them curved and they naturally want to hinge along the weld. Maybe you could brace the panel to stiffen it so it cant distort so easily, its only a couple of Bar after all. I spose if it was a pressure vessel it would be round and wouldn't try to change shape..

[GT500]

The weld should not crack. I would suggest the wrong filler rod has been used.
A correct weld is stronger than the two parts its joining.

HtH

[Jamo]

The weld should not crack. I would suggest the wrong filler rod has been used.
A correct weld is stronger than the two parts its joining.

HtH

A lot of Ali manifolds crack under pressure on the S2.

There have been about 10 reported cases on here not least a certain h@cke manifold

[GT500]

A lot of Ali manifolds crack under pressure on the S2.

There have been about 10 reported cases on here not least a certain h@cke manifold

That I don't doubt, Its where they have cracked. If the fabricated manifold cracks its from flexing as the boost goes up and down. It should crack at the most point of movement.
A correctly done weld should not crack.
Just trying to help, might be nothing wrong with the design of Marks mani, just let go due to bad workmanship.