Wastegate advice

[milldog]

I am going to be bringing my 38mm Tial wastegate right off a 2nd gen manifold. What technique do you recommend to weld the tubing I will be using to the cast manifold? I was thinking having someone O/A weld it but am worried about warping. Also do any of you have pics of a setup similar to this.

Thanks

 

[Dockboy]

Use ductile steel pipe to weld to the cast manifold not typical exhaust tubing.

 

[milldog]

Use ductile steel pipe to weld to the cast manifold not typical exhaust tubing.

What welding process did you use to minimize warping the manifold or is that not an issue?

 

[tony597fitter]

You would be better off doing a wastegate adapter plate like the one Engineered Diesel sells or doing a custom carbon steel sch. 40 manifold, than trying to weld cast iron.
Trust me it SUCKS! I have done it a few times in the field and alot of the time it cracks and then you are chasing them out.

Here is a good article I have saved.
http://www.lincolnelectric.com/knowledge/articles/content/castironpreheat.asp

 

[CL2000]

Sylican bronze rod with a tig will do the trick just fine

 

[Dockboy]

What welding process did you use to minimize warping the manifold or is that not an issue?

I will ask my buddy who I had weld it. The weld must be needled though.

You would be better off doing a wastegate adapter plate like the one Engineered Diesel sells or doing a custom carbon steel sch. 40 manifold, than trying to weld cast iron.
Trust me it SUCKS! I have done it a few times in the field and alot of the time it cracks and then you are chasing them out.

Here is a good article I have saved.
http://www.lincolnelectric.com/knowledge/articles/content/castironpreheat.asp

Mine is solid as a rock and not cracking one bit. Secret is the fitment. I used a hole sale to cut the hole in the manifold and the ductile steel pipe fit tight in the hole.

The ED piece is very nice and I would recommend it. Just wasn't avaiable yet when I built mine.

 

[Big Blue24]

You could always do a high temp braze. I think you can find stuff that melts around 1600*. Your manifold should never hit much more than 1200 unless you're building a land speed record truck that might be WOT for minutes at a time.

 

[JQmile]

I'll see if I can get some more info from the guy who did mine...I know they heated up the manifold pretty well.

 

[CL2000]

Jason,Looks like the sylican bronze rod was used on that.

 

[milldog]

Thanks for all the responses guys!!