Exhaust Manifold Reparing

[hebdena]

Evening All,

Has anyone had any experience of repairing a rust hole in an exhaust manifold or having one repaired ?
My MD2B manifold has developed one. I have plenty of welding experience with sheet steel etc and one bad experience of welding a cast manifold. It cracked when cooling!

Regards...................Andrew

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[Heckler]

i took mine off my vp2030, looked at it, thought about brazing, welding and then thought about the consequences of the water going the wrong way into the cylinders or leaking into the boat halway across the irish sea and said sod it, bought a new one, check with volspec and keyparts, they both supply the genuine parts but can do better than each other on different parts, i was quoted £169 by one and £103 by the other.
stu

<hr width=100% size=1>http://www.beneteau-owners-association.org.uk

 

[Martin_e]

Is it the bit which has the cooling water "injection". If yes then get a new flange made in 10mm steel and weld up a couple of bits of pape to make a new one, if not oh dear. I made mine up from Duplex SS. Looks good and will not rust.
Welding cast is difficult,but there are soom good rods available and ai understand it is a good idea to heat the lump up first and let it cool down slowly. I have done it without cracking before.

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[aztec]

dunno if this'll help but...

use Inox dx rods (or simmilar) made by oerlikon (sp?) heat the lump to be welded first then build up layers slowly, if you need to finish the welds between beads grind back but keep the heat in.

otherwise prepare the matal with a decent grinder, heat, and use silicon bronze rods... they have a rough exterior (a bit lke High tensile steel rod) don't finish the brazed repair, let it cool gently.

i have used both methods to repair/reshape combustion chambers (showing my age now!) and both have worked successfully. if all else fails, you will need to replace the offending bit... so bit of a "nothing to lose by trying" thing.

regards, steve.

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[Keith]

Irepaired mine using silicone gasket a peice of brass sheet and three jubilee clips, ran like that for three years without any problems at all..........keith

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[maxi]

Am afraid that you will end up replacing sooner or later. Don't bother with Volvo's own product which is a c..p casting to start with. A new stainless steel injection elbow for my MD11C cost me £70 whilst I am having a high-lift stainless injection elbow made for a Kubota at just £100 - both infinitely better value than Volvo products.

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[LORDNELSON]

I would be grateful if you could say from where you obtained the s/s parts; are they specially made or from a parts supplier?

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[Aja]

Have you thought about Chemical Metal?

Donald

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[maxi]

Re: Lord Nelson

Whilst I have made injection elbows from a concoction of threaded tube and off-the-shelf elbows and they worked, they were still a concoction.
There are, to my knowledge, no specifically prepared parts. Almost any stainless steel fabricator will be familiar with manufacturing a bespoke item for you. The high-lift elbow that I am currently having built was stated as being: just a couple of hours labour, a bit of tube and 3 bent elbows Mate, by the man with grubby hands!

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[LORDNELSON]

Re: Lord Nelson

Thankyou, I will have a word with our local S/S welder.

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[hebdena]

I think I'll get a price for a replacement manifold first before I attempt a repair. It is the actual manifold that has a hole in it on the underside just aft of the thermostat.
The hole is quite close to the core plug which could present problems. I'll assume that if I have one rust hole then the manifold may be a bit thin elsewhere so the new manifold option may be the bset.
Thanks for all the replies.

Regards............Andrew

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[hebdena]

I think I'll get a price for a replacement manifold first before I attempt a repair. It is the actual manifold that has a hole in it on the underside just aft of the thermostat.
The hole is quite close to the core plug which could present problems. I'll assume that if I have one rust hole then the manifold may be a bit thin elsewhere so the new manifold option may be the bset.
Thanks for all the replies.

Regards............Andrew

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