2 piece EM welding, skimming, and coating

[Jörgen Karlsson]

Phil wrote:

> In my experience, welding is very rarely successful.


I don't think that the proper welding procedure are used very often, it is a
PITA to weld cast items.

First the part should be normalized, this is never done!

Secondly the part should be _very_ hot while it is welded, one way is to use
two welding torches to keep it (red)hot, while you weld it with an electric
welder with suitable electrodes. Of course powder welding the part while it
is hot is the best alternative, but it is hard to get someone that has the
equipment for powder welding.

Now the part should be normalized again... Most likely it is now badly
warped and needs to be milled...

If this is done the manifold will probably be as good as new, or a lot
better!

Anyone that has seen a welded part being normalized understands why welded
manifolds tend to crack...


Jörgen Karlsson
Gothenburg, Sweden

For sale:
New K24-7000 turbo(S4), MC exhaust manifold, wastegate, downpipe.
Used K26 turbo, MC exhaust manifold, wastegate, downpipe.