Outer Limits 4x4 Board

want to re weld a crack in a cast zorst manifold
so whats the go?
any tips
obviously its tricky to do, thats why im asking......

Not an easy job for the "unexperianced" but not imposiable either.

Zorst manifolds tend to get nasty chemicals from the exhaust gasses leitching through the metal, this makes it tricky to weld as such.

Best bet is to "bronze" up the crack using an oxy accetlene.

Get a grinder and grind off the crud around the crack ( about 1/2 an inch clearance all around the crack would be nice)

Grind out the crack so its a "V" shape and to a mimimum depth of about 2/3rds of the thickness of the manifold
( example: if the manifold is say 6mm thick then grind down into the crack to a depth of 4mm and vee that grind out to a width on the surface of about 6mm, this will give you a good strong weld area)

Cook the manifold ..... in other words "preheat it " , shove it in the missus oven on high heat for an hour or warm it up gradually with the oxy set. Alternativily if posiable leave it attached to the motor and just run the engine up to normal operating temp and weld it while its still attached to the motor ( yeah i know thats not always possiable but it sure is a lot quicker at times ! )

Bronze up the crack in the manifold while its hot and when you finish the welding re heat it again all over and try and control the cooling down of the manifold so it cools down slowly.
If it cools to quickly you may get another crack .......
ofcourse a set of new extractors might be better

Kingy

V8Patrol wrote:shove it in the missus oven

Don't be a tight a--e Steve, get some extractors! Ferozas have a habit of doing the same thing (mine did...) all the research I did suggested welding is rarely successful. It was a good excuse to justify buying extractors.

Is this on your current engine or the one you're planning on transplanting in?

Yeah but sometimes it's fun filling things with weld

Dave its for the engine thats goin in....

unless i could get emission legal extractors, it not on the cards yet

remmeber i gonna have to drag my a$$ through regencey when im done, not lookin forward to it, but im gonna do it legal tho, do not need to give them reason to get upset......

I believe somewhere along the model line up (VN-VY) there was a revision to the exhaust manifold design to stop the cracking. So possibly a wrecker might be the go? Would standard Commondore extractors fit in your engine bay???

I don't see how Regency could fail you for extractors? They're not illegal and don't change any of the emissions or anything like that. You may get a bit more exhaust noise, but it wouldn't make it illegal.

I work for holden, and pretty sure that there was a revised manifold. If ya can wait till monday i can get the engine numbers and build dates that the revision came in at or any other info if that is a help to ya?
Let me know
Layto....

layton - im keen for any info you can get - thanks

Dave extractors will fit, but i was sure regencey would knock me back for extractors.....?

Extractors aren't illegal (and guaranteed to be cheaper than new manifolds from GMH!!). Providing you keep the oxy sensor in the system there should be no problems.

However they will get you for your tyres- anything over 15mm larger diameter is illegal.

sw1... i love your pic man... freaked me out.. was boozing and listening to thje Prodigy in me ears... and it was IN TIME!!!!!....

faaaaarr out....lol


sorry off topic, i know...













was just realy freaky...

sorry, ill go now..

murcod wrote:However they will get you for your tyres- anything over 15mm larger diameter is illegal.

Unlikely that you will get knocked back for over diameter tyres, unless it significantly affects braking performance. That doesnt mean they approve of it though. Seems to be a couple of different opinions within TransportSA.

I made some enquiries a while back with Transpsort SA and 15mm is the ruling..... Tried finding an engineer to do it legally without much luck either- one was talking about slalom tests, brake test, emissions test, drive by noise tests, etc , etc!!!

So, from that info, I assume there are a lot of illegal 4WD's driving around over here! Steve needs to get his engine change approved and get his vehicle inspected at Regency, so highly likely they'd ping him for the tyres.

tyres arnt the issue fellas
the issue is a cheap fix for a cracked exzorst manifold


btw aj thats one tough patrol!
i like it, i like it

Hey Kingy!

I know what you called your description "bronzing", but is that also known as brazing? What kind of filler rod does this use?

I ask coz I did some oxy welding a few months ago at TAFE and the brazing we did was not suitable for applications where the weld was exposed to temps over 250 deg (or was it 280).

Are we talking about the same thing, or is it just a different filler rod or am I totally off track?

Dave, i spoke to regency - & they faxed through some info. they are ok with extractors as long as sound and emissons not altered

already got the 'right' price for a set of new advance extractors..... $260.00

sweet
new studs and gaskets and im all good

$260 is a bargain considering it's a V6- my Feroza ones were $275 for an inline four.

Providing emissions testing is done on a steady cruise speed there shouldn't be a problem. The oxy sensor will kick in and control the mixtures once you're up to temp and doing a steady speed.

Do they actually do emissions testing to approve it- or is it as long as you run the standard EFI system it's deemed OK?

Sound level should be OK as IIRC the older your vehicle is the louder it can be.