RE: 64 wedge exhaust manifold

["Raymond J. Henry" <62Dart@xxxxxxxxxxxx>]

Yes. But evidently, it's tricky. Because of the materials used in exhaust
manifolds, it can be difficult to do. It's often porous and hard to match. I
have a friend that is one of the best welders around these parts who has
done many (he did work welding on aircraft engines for a while). I'm unaware
of any that have failed.

What he does is prep the manifold first by getting it as clean as possible,
and removing some of the outside material (so that when the parts are fitted
together, a "v" groove is there). After prepping the crack, he preheats the
manifold as much as he can using any type of oven. This is to get even heat,
as "spot" heating with a torch can dissipate too quickly. Then his choice of
welding is oxy/acetylene, and an old wire coat hanger for rod. On the
mounting face of the manifold, he makes sure that he does not develop a bead
that reaches the surface. Close, but not quit. This is in case the manifold
needs machining. The weld doesn't interfere.

When he's done, he lets the manifold cool naturally and then removes any
weld bead that may interfere with bolts, etc. Then it's checked for being
true and machined if needed. He's repaired a ton of them this way, most
after they have been rejected by pretty much every machine shop/welder in
town. He's probably done 8 or more for me, all of which have never failed.

So check around, my bet is that you will find that one welder near you that
does the stuff nobody else wants to touch...

-Ray


-----Original Message-----

Just got back and the shop got them down so they appear good to go.  will
put the engine back in car and give them a try. Have the other set with the
cracked ears. Any one ever fix that???  Dave O

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