Very basic welding question

colinml · Feb 15, 2011

One of the ports on my exhaust manifold (1959 Case 510B) is slightly warped so that the surface which mounts to the engine is not in the same plane as the other ports on the manifold. There is a gap of just less than 1/8 inch. I think the correct fix is to build up some material on the port's mating surface with a welder, and then flat file the material flush with the other ports so that the manifold will seal.

I've never welded before. I have a Hobart 140 Amp MIG welder that I've been meaning to learn how to use. Should I use argon? Or a flux core wire? What is the risk that the cast iron will crack? Is there a special wire for this purpose (cast iron)?

Thanks,
Colin

36F30 · Feb 15, 2011

Take it to an engine shop and have them plane it and be done.

Anonymous-0 · Feb 16, 2011

I think 36f30 is right. i think you would have better results by having it surface ground or planed. They can make it perfectly flat.

colinml · Feb 16, 2011

Oh, ok. Machining makes more sense.

thanks

JDseller · Feb 16, 2011

That manifold will NOT weld with a MIG welder. Really not weld with a 140 AMP welder. Like others have stated get it machined flat.

Chris(WA) · Feb 16, 2011

A good muffler shop will have a machine for surfacing that manifold and may be cheaper than a machine shop.

Blackhole49 · Feb 16, 2011

Several years ago I did an 8n with brazing rod and it lasted about 10 years until the manifold got so thin it just let go. It's what will work when you have 0 dollars.

Wilson · Feb 16, 2011

are you the beatty i grew up with??

James Baughman · Feb 16, 2011

Pre-heat with torch then use arc rod called "99 nickel." Go to your local welding supplier and let them give you the name of a good local welder if you don"t feel comfortable welding it yourself. HOWEVER, check the cost of a replacement part first. A 1 lb tube of 99 nickel 1/8 inch rods is about $40. There are about 12 rods to a tube and it works out to about $3.50 per rod. Add on a minor charge for gas for pre-heating and add labor and you can easily spend over $150. You may be able to buy a new replacement cheaper.

DH in Carolina · Feb 16, 2011

I would try doubling the gaskets under it and run the engine under a load to get it hot. While hot tighten the manifold bolts a little. Repeat this a few times and it may pull back in line. DH

James Baughman · Feb 16, 2011

A link to the correct nickel welding rod on Amazon.com 4 rods for $6.95. In case the surface needs to be built up before machining.

http://www.amazon.com/Hobart-H500644-RDP-Nickel-Electrodes-8-Inch/dp/B00012X8OM/ref=sr_1_6?ie=UTF8&qid=1297875788&sr=8-6

BushogPapa · Feb 16, 2011

If you have Never welded, do not start learning on your manifold..!!
Those with years of experience will not attempt to weld cast Iron..

Ron.

Adirondack case guy · Feb 16, 2011

Thats a good way to break the bolt flanges rite off the manifold. have it plained.

DH in Carolina · Feb 16, 2011

Not if you know what you are doing. DH

colinml · Feb 16, 2011

Thanks for bringing me up to speed. I'm going to return to plan A and learn welding by making a welding cart. As for the manifold, I actually tried ordering a new one, but after several attempts, have not been able to get the company to send me the correct parts. After a month of trying, I've given up on that route. Ill head over to a local exhaust shop today and see if they can machine it for me. Thanks again for the help.

Jerry/MT · Feb 16, 2011

You might consider having a machine shop shave the faceof the manifold true. Welding cast stuff takes controlled cooling to keep it from cracking. I"m sure the experts here can tell you hw to weld it correctly but then you"ll hav eto machine it to get everything flush. and "in plane".

gab · Feb 16, 2011

Have a machine shop plane it, just had one done for a Super M for $30.

Fred Martin · Feb 16, 2011

I surely would like to get thirty bucks for doing that job. As necessity is the mother of invention, I put one on a belt sander that I made, had a long piece of 3" wide flatiron backing up the belt with 72" belt, 60 grit. I worried about a day on how I was gonna set it up to machine in the Bridgeport or the horizontal milling machine. Took all of about one minute to put her back to flat. All of you can store this one in your memory bank! Piece of cake if you think about it. Don't know if I was the first to ever do this but, we can all do it now. You're welcome cause I know you are gonna thank me for this one. ohfred

Anonymous-0 · Feb 16, 2011

Cast iron takes proper preheat, interpass and slow cooling temperatures. Can it be successfully welded? Yes but unless it's done by someone with a lot of experience, there is always the chance that it will crack or break again. Dave

Anonymous-0 · Feb 16, 2011

Wilson I grew up & live around LaPorte,in.

Leroy · Feb 17, 2011

Never heard of a muffler shop doing that, engine shop yes, muffler no.

colinml · Feb 17, 2011

Well, the machine shop said it would have been quite a bit of material to get things flush, so I decided to give it one more try with the company selling new replacement manifolds. I ground off the bolts, and ended up with a good intake manifold, and I should have a new exhaust manifold end of next week. Of course, I may end up needing to have them machined anyway...

Very basic welding question

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