DamirGTI 342 Posted September 28, 2007 Hello ! Please can somebody help me out , I need advice regarding exhaust mainfold repair . It's OE Peugeot exhaust mainfold and it blows out at the corners , I've try all sorts of mainfold gaskets , sealants etc. but all of them was just temporary fix for 5-6 months and it started to blow out again .. Well the problem is because contact surface of the mainfold isn't flat on the two end corners , it haves 2-3mm deep craters from where it blows gases out (you can see that on pictures as black areas on the corners ..) , and I can't seal this surface to make long term gas tight seal with any brand of exhaust mainfold gaskets or high temp. gasket sealants .. So I'm looking for some tips on how to repair this manfold surface on the corners ? Can I mill/grind entire mainfold 2-3mm down in order to make fresh flat contact surface ? Or can I just weld this craters on the two end mainfold corners and then grind this welded area back down to the original contact surface ? Something else maybe ? Thanks !! Damir pics : http://s27.photobucket.com/albums/c151/Pie...stmainfold1.jpg http://s27.photobucket.com/albums/c151/Pie...stmainfold3.jpg http://s27.photobucket.com/albums/c151/Pie...stmainfold4.jpg http://s27.photobucket.com/albums/c151/Pie...stmainfold2.jpg Share this post Link to post Share on other sites
jeremy 70 Posted September 28, 2007 Possibly weld then skim, if not then just skim and new gaskets. Share this post Link to post Share on other sites
Baz 421 Posted September 28, 2007 Tried Loctite 5920?? It can be welded but as it's cast it's a specialist job, may be difficult to get hold of for you but you may be better off getting a replacement. Share this post Link to post Share on other sites
DamirGTI 342 Posted September 28, 2007 Hi ! I've been welding this cast exhaust mainfolds before (well not this one but the spare one which had one crack inbetween 1-st and 2-nd cylinder ..) first i was preheating the mainfold in the oven up to 200-250C and then preform welding (with special welding rod for cast iron ..) on hot mainfold and it was good no problems what so ever after the welding , like brand new item ! .. But this mainfold is the best of all i have apart from that contact surface imperfection So what's this Loctite 5920 ? some sort of high temp. liquid metal ?! does this stuff works @jeremy Yes i was thinking just to get it skim down a bit , but i don't know how much is allowed for cast mainfold skim what i mean can it beak after when it gets hot or something ?! (if it's skimmed too much...) Cheers ! Damir Share this post Link to post Share on other sites
jeremy 70 Posted September 28, 2007 I have used a skimmed one before, I will try an measure the thickness for you tomorrow if I can find it. Share this post Link to post Share on other sites
steve@cornwall 100 Posted September 29, 2007 Not sure on the skimming etc, but I'd replace the mounting studs in the head as I've had manifolds warped like tis before, and only noticed when the studs have broken. Some have been warped enough not to fit on good studs (when fitting s/h manifolds) and have needed the holes enlarging to fit comfortably Share this post Link to post Share on other sites
DamirGTI 342 Posted September 29, 2007 Hi ! All exhaust mainfold studs are replaced this year when i was rebuilding this engine Share this post Link to post Share on other sites
DamirGTI 342 Posted September 29, 2007 I have used a skimmed one before, I will try an measure the thickness for you tomorrow if I can find it. If you can - please ! it will be nice to know Did you have any problems with that skimmed mainfold ?! ( bending , distorting , cracking , blowing out etc. ?! ) Thanks ! Damir Share this post Link to post Share on other sites
jeremy 70 Posted September 30, 2007 Ok sorry for the slow response. Just measured the thickness from the mating edge of the manifold to head to the face where the manifold stud nuts srews upto. The reading is an average of 10.5 to 11mm thick. When on the car I never had any problems with leaks. Hope this helps you. Share this post Link to post Share on other sites
DamirGTI 342 Posted September 30, 2007 Ok sorry for the slow response. Just measured the thickness from the mating edge of the manifold to head to the face where the manifold stud nuts srews upto. The reading is an average of 10.5 to 11mm thick. When on the car I never had any problems with leaks. Hope this helps you. Hello ! Yes excellent , thanks a lot Jeremy ! Regards Damir Share this post Link to post Share on other sites
