5KTQ Cracked Exhaust Manifold and upgrades

[Haydn Taylor]

Hi all,

I have just stripped the motor out of my 86 5KTQ as I was so close to having
it out after stripping the head and ancilliaries that I thought I may as
well.

I had to remove the head in order to get the exhaust manifold off as the
nuts on the underside of the manifold were completely corroded from exposure
to the heat of the turbine housing. Now its off and I have had a look at it,
there are a number of small cracks in the manifold (see link below for
photos)

http://thepointoforgasm.com/gallery/Audi-5KTQS/aco

(this is my gallery site that has a lot of photos of the work so far on the
audi amongst other things)

So here's the thing....what do I do about them?

A) replace the manifold, but I am guessing from my research to date that
this is a common problem and even if I find one that isnt cracked, at some
point it will be

B) have it welded and strengthened

C) I heard of a solder solution that is allegedly good to 1200 degrees. I
have no experience with this but I dont think that is high temp enough

D) Is there a manifold from a leter vehicle that would be a better swap for
the kkk charger

E) Tubular manifold - build one or buy one?

F) ceramic/metallic coating after welding to reduce heat transfer and keep
the hot gasses in the manifol hot and in the manifold

any advice would be helpfull.

p.s. I am rebuilding this car for fun, not to win concourse comps so I will
be looking for more power and changing quite a few other things out.

Thanks

Haydn

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