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How To Weld Cast Iron Exhaust Manifold

Thoroughly clean the surface to be welded, grind, file, dress, and dry. Grind the area to be welded.


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When doing this, you can take your glove off after the bead & lay your bare hand on the weld &.

How to weld cast iron exhaust manifold. Immediately after the 1 inch of weld, we “shot peened” with air hammer and pointed chisel. This removed the slag and left the surface of the new weld dimpled. Low and slow is the key to a sound weld with cast iron.

We used a powercon 350 dc welder at about 70 amps, and welded 1 inch at a time. To maintain a nice weld, use the mig welder to maintain the lowest feed rate and the lowest current. The manifold is made from good quality thick material, so it’s a good candidate for repair.

I vary location with each bead with immediate peaning. Grinding the cracked area of the manifold removes any debris or rust that may have built up in the surface of the crack, and also provides a clean place for the welder to create an arc. Just grind until the cracked area of the manifold is clean and ready to weld.

How to weld cast iron with a mig welder. Using this torch you spray the powder through the tip of the torch after your base metal turns to a red heat and the powder fuses to the base metal and melts creating a bond without porosity and without bringing up all the junk in the casting. In the past i've been drilling stop holes at the ends of the crack then veeing them out with a die grinder, pre heating then tig welding them with some coated 309l filler i've had around for so many years now i can't remember who made them or where i bought them then some post heat and pack in sand to cool.

Please observe all aws safety & health guidelines when using muggy weld products. For cast iron, there are two main types of stick welding rod 55 percent and 99 percent nickel. To achieve the best seal, create a flat braze.

The idea is to weld in very short beads not exceeding 1/2, peaning immediately, & allowing to cool back to room temp. The replacement manifold is $285. We cleaned a 3 to 4 inch cut, then silver soldered the cut with an oxyacetylene torch.

I've also used it for building up worn cast iron pulleys for machining new surfaces onto them. Fixing a broken cast iron part. You can weld cast iron by stick or oxy.you can’t just weld it, cause it will crack right next to the weld.you don’t have to worry about slag since there will be no flux when welding your exhaustyou exhaust manifold is most likely nodular iron.

Rust hole in cast iron exhaust manifold. For some cast irons you may only want to weld an inch or less and let cool 1 minute between passes. It is thin in that area.

You’ll need to be careful when welding cast iron metals like exhaust manifold with mig welds. Don't grind too much material away. Always weld no more than 2 inches at a time and let cool for 2 minutes between passes.

The hole is buried within the top of the casting, and is a case of the water on the top of the manifold collecting water, and rusting. That is a 4 year old price, and it may or may not be available still.


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