Cracked EM

[Aleksander Mierzwa <alex@matrix.pl>]

Hi List!

It seems that if you own an old Audi, you simply _have_ to face some
typical problems. Yesterday while crawling under the car I discovered
that my exhaust manifold is cracked right at the #4 flange. So, I need
some advice on possible repair methods.

1) Has anyone had good effects with welding? I've heard that the old
style 5KT manifold is prone to warp by design and it will crack again
even if welded and machined. True/not true?
2) I, therefore, consider finding a used two-piece manifold (I cannot
afford a new one. I cannot, period). I understand that the two-piece
unit doesn't warp and therefore buying a used one is fairly safe. Good
idea/bad idea? Which Audi models was the two-piece unit fitted to? Would
a manifold from a 200T20V/S2/S4 fit my 5K? Could someone please pass the
p/n for the correct manifold to me?
3) Fortunately, I don't see any broken studs (yet ;-) ). If all studs
are intact, can I leave them in place or should I better renew them?
4) What do I risk if I drive the car in this condition? I can't hear any
exhaust noise from the manifold.
Any advice will be greatly appreciated.

Aleksander Mierzwa
Warsaw, Poland
mailto:alex@matrix.com.pl
87 Audi 5000CS turbo (mine)
88 Renault Medallion wagon (mom's)
91 mountain bike (just in case both cars broke at the same time :-)