mk1turboestate

iTrader: (2)

i have been fitting a zvh turbo in a mk2 escort estate and the turbo was facing the wrong way so i flipped it which ment i had to cut and reweld the elbow, do you think this will hold???

mk1turboestate

iTrader: (2)

check out the rebuild https://passionford.com/forum/restor...-rs-turbo.html

boothy

iTrader: (14)

doubt it

scottyrs

iTrader: (1)

i woulnt want to chance it

Chaz888

Only know of one job like that that held he heated the item in his oven then got it well hot with a torch done the weld then back in the oven for hours on a slow cool down all was good it was on a mgb with a tubo d 1.8 in it

mk1turboestate

iTrader: (2)

whats the best way to stress it cos iv heated it back up and been hitting it with a hammer to try and crack it

does anyone no what its actually made of? because with the mig on its highest setting it welded perfect, not one crack and penatrated rite through

e30cossie

Did you use special rods for welding cast iron ?

Chaz888

thare cast iron seen it done with stick and correct rod type but not mig ????

mk1turboestate

iTrader: (2)

no, i used a mig, not sure what the actual content of steel to iron is?
the car wont run for a few months anyway but i need something for mocking up, but was hoping it mite work

Chaz888

Have a word with a good welder cos I think that just wont hold

mk1turboestate

iTrader: (2)

i have spoke to a couple of welders but they said just try it, i no somebody who can cast weld it for me and mite end up doing that at a later date but i wanted to no if anyone had tried it, u never no

mk1turboestate

iTrader: (2)

anybody done it?

crumpet

My mates got a t16 turbo engine which has a td04h from a evo welded onto the standard cast manifold, thats non gas mig'd on and thats holding PMSL

KnoxyGtt

i know a guy the modded a standard let turbo manifold, cut it at the kneck and welded a t3 flange onto it, he heated it up before hand to try and stop is cracking, then used mig brazing wire on it, think it held up for ages but he suported the turbo so there asnt alot of stress on it.

jamie rst

iTrader: (1)

Mig weld is no good on cast mate,it needs to be done with a cast rod mate and there are not many peeps around who do it well thats in nottingham anyway i found two companys that would do it and it's not that cheap i had my old mans cosworth manifold done it had a 2" crack in it and it cost about £50.

mk1turboestate

iTrader: (2)

its not the actual manifold, its the elbow that goes down to the downpipe, i used gassless mig wire because i read that this works better,

does it crack straight away?

i heard no tink tink noises and the welds are still perfect, it also penatrated really well so was wondering if it had i high steel content

Sp3no

iTrader: (1)

When the steel from the mig cools down it does so much faster than the cast and contracts, you may hear some tinkling noises coming from the casting as it cools, the noise is cracks forming, the best way to weld cast with mig is to braze it, you need to heat the cast up to over 700degrees and then let it cool down very slowly in an over to save the cracking. BUT mig is by far the best way to weld cast and it should be done properly.

mk1turboestate

iTrader: (2)

well i suppose i will leave it for now, anybody no a good way of testing it?

eg. heating it up and knocking it?

caprizetec170

not Sure if it'll hold mate we do a bit of work restoring old gates and the like. Normally we'd just grind out the crack heat the whole item till it just starting turn red weld it with a dissimler metal rod them keep gently heating it and leave it in a bucket of sand to cool down, Migs are normally notgreat for cast cause all the heat is concentrated on one spot.
BUt on the other hand ya might be surpised a lot depends on the actuall iron nickle content and other things in metal

mk1turboestate

iTrader: (2)

thats what im hoping for, but cant really test it till i try it

KnoxyGtt

put it on and see if it works, if not then back to square 1 lol

swoosh500

As capri zetec 170 says, best heating the material before welding and then using a dissimilar welding rod with an arc welder, not mig and let cool down gradually, this is the best way for cast materials.

mk1turboestate

iTrader: (2)

to late lol, i pre heated it and cooled it down slowly but used a mig with fluxed core wire on the hottest setting, got no cracks and no noises, if anything it welded perfect like to pieces of steel,

crumpet

Fuck it pal try it, prove us wrong lol, if it fails get a t34 and use a cossie ss down pipe

botters

iTrader: (2)

ive welded cast with mig before using the heating cooling method with an oven and have had no problems allthough i have heard of the cast exploding before when cooling! not nice if its under your bonnet!!

mk1turboestate

iTrader: (2)

im going to wrap the elbow tightly anyway just in case cos i dont want it dropping near the paintwork,

zippyobrien

iTrader: (2)

ive welded cast before with a mig and has been fine, just heated it up till it was glowing, also filled a chamfure on to both faces to get better penatration.

that was welding a zetec flange onto a rs turbo manifold and it was fine,
give it a go, it it leaks \ cracks then you can use it to mock up a steel one, just get some flanges and a bit of bent tube.

lee

mk1turboestate

iTrader: (2)

nice to see somebody who its worked for,

i cant do it in steel tho as its part of the wastegate housing

did u have any cracks or problems?

jamie rst

iTrader: (1)

i know its the elbow your on about i was just saying that i had a cast manifold done as cast is cast at the end of the day

zippyobrien

iTrader: (2)

ran the manifold for ages and it was fine,

all i did have to do was skim it flat on a mil as i warped it a little bit, bit that dont apply to your application

mk1turboestate

iTrader: (2)

gives me hope mate nice one, seems strong to me anyway but will be months till i run it

zippyobrien

iTrader: (2)

leave it out side, let it weather'

thatll show if its strong or not lol

mk1turboestate

iTrader: (2)

thanks for everyones input, guess i will just try it n hope for the best, couple of people have had positive results so hope i do!!

KnoxyGtt

http://www.mig-welding.co.uk/cast-iron.htm

mk1turboestate

iTrader: (2)

thats a good read, i tried for hours to find something like that