I am attempting to weld my erst manifold to my Rs2000 exhaust flange and I have be advised against it as it is cast iron and would be weak..
I have seen it done before with no problems..

Has anyone had cast iron welded in this type of application and had problems??

 

to do it properly powdered iron rods [arc] pre heat weld hot cool naturally if welded normally it nearly always cracks just beyond the weld

 

i use this place for all my speshol welding stuff and i no they have welded cast in the past

http://www.bropel.co.uk/

 

Good advice, not done it myself but I know people that have and having it very hot when you weld it is key to it working.

 

get it hot to around 200-250 degrees and weld it immediatley then put back in the oven and bring heat down ten degrees every 5 minutes or so until cool or leave to cool by covering it completley in sand, mig welding is fine if done this way but you have to be aware that while cooling it can still crack, usually accompanied by a loud bang lol!

 

Do you mean MIG with just a normal mild steel wire, or do you need a wire with higher than normal iron content?

 

ive used mild steel mate not ideal but it works (most of the time!)

 

Cool tip!

 

Even when welded as above it can and most likely will still crack9again), due to thermal shock, made worse with certain designs, but very small cracks can often be ignored.
tabetha

 

it depends on the cast material, cast iron will have more of a tendancy to crack, cast steel (like most manifolds) will be better to weld, i had an erst turbo elbow welded before, for an lambda boss, and it was perfectly fine, would it not be easier to make an adaptor plate or re drill and tap the head for the studs?

 

I've done this but with a zetec flange. As said get it really hot. And use some of that anti slayer spray.