Turbo headers - Welding pipe to stock mani.

[Mars]

I've been researching alot on other sites (LS1tech, turbomustangs)for this idea and I think it'll work, but wanted to know if anyone here had real life experience with this.

It's about welding normal steel pipe to a manifold. Seems the newer (ish) manifolds are made of a nice carbon steel that welds very well.

I tried a test here, and it worked well (i think ?) This was no prep, no pre-heat, no slow cooldown, no nothin'. 2" 16ga. aluminised pipe to a 3900 manifold that I cut apart. FLUX CORE MIG, you can see by the spatter.



As you can see it layed a nice bead down, the welder worked well, nice puddle, not much spatter, ect. i think it would be tough as all hell. After it cooled I grabbed the biggest hammer I could and demo'd the thing and it didn't break in the weld. It tore the smaller pipe just above the weld, which is precisely what I predicted would happen..

As I build this 3900 turbo engine, and do the turbo pipes, I am starting to think I'll abandon the custom header idea and use manifolds. I may even do something super-custom for the driver's side that I have planned IF this manifold welding thing works...

I was thinking of using steam pipe SHC40 in a 2" and just welding it right to the manifold about a 100* angle right into the T4 flange about 8" away.... With just enough room for a gate, all one piece, fully welded for the pass side, then a V-band and flex heading to the pass side off the other side of the divided T4 flange.





I'm thinking it would spool quick in that location... 3.5" exhaust would be going alongside the alt. then down.

[ericjon262]

I don't have much to offer on the welding durability, what you have done looks pretty damn good though. how much clearance do you have between the manifold and the idler pulley? other than that, looks good!

[Mars]

Oh, there's lots of room there, it's just that the pic is deceiving due to the angle, for sure 3/8".., plus that is the idler that acts as a tensioner, so when the belt has a few hours on it, I should be able to clock it over another 1/4" at least.

[ericjon262]

10-4, what are you doing about power steering?

[Superdave]

He's going manual..

Weld looks good, you'll never really know until it heats up though. As long as the 2 pieces expand and contract at a similar rate it should be ok.

I'd make every effort to clean both surfaces as well as possible though, don't take any chances.. lol

[Z26-T]

*drool...* Hard to say if it'll hold or not, as stated by Dave. From the looks of the weld, I'd think you'll be fine. I had a welder do something similar with my first set-up, but I ending up using full headers. He said the welds on the cast manifolds wouldn't be an issue though.

[Mars]

*drool...* Hard to say if it'll hold or not, as stated by Dave. From the looks of the weld, I'd think you'll be fine. I had a welder do something similar with my first set-up, but I ending up using full headers. He said the welds on the cast manifolds wouldn't be an issue though.

Are you drooling at that delicious case of MGD ?

Yeah so I'm happy with these answers.. I'll go ahead and try it.

[dskopek]

I have had good results using SS welding rod when welding cast iron to carbon steel. Both arc welded and TIG. Old timer told me that was the only thing he would use on cast iron if he did not want it to come back to the shop for repair. So far I have seen the same thing.

[Mars]

I have acces to a stick with that rod. I can tack it here and goto my old mans and weld it up with the stick. I just wonder if it's worth the hassle..... hmm

[Superdave]

I forget the stick number but there is one with high nickel content that's supposed to be used for welding steel to cast iron.

[timg]

I've done something similar. My stock crossover flanges were welded to the crossover pipe. I also had a front manifold cut up and welded to a 3/8" flange. The crossover has survived many miles with no problems. I'm not yet sure how the manifold will do.

Tim

[Mars]

I've done something similar. My stock crossover flanges were welded to the crossover pipe. I also had a front manifold cut up and welded to a 3/8" flange. The crossover has survived many miles with no problems. I'm not yet sure how the manifold will do.

Tim

MIG TIG Stick ??

[TGP37]

For what it's worth, I welded the flange and box to the stock crossover from a 3100v6 96. So far it holds up pretty well, no leaks or cracks....yet. I only have roughly 200 miles on it driven hard in boost.

I also welded the 1-3-5 exh manifold closed at the merge out. That to holds and has held for 3 years so far.

[ForcedFirebird]

14ga mild steel to cast iron.





Still together after the guy blew up his car, was running it for a year.

Cast iron cat turned into turbo adapter.



Cast iron N/A down pipe turned into turbo dump.






TIG welded with 3/16" mild steel filler. 200amps, no pre-heat (although I let the torch sit for a bit before filling), no cool down.

[Z26-T]

Are you drooling at that delicious case of MGD ?

Yeah so I'm happy with these answers.. I'll go ahead and try it.

Haha. nope, not the MGD. Drooling over the water pump and polished brackets. Almost makes me want to replace the SBC in my camaro for a 3900... almost .