Concerns about sealing between exhaust mani & turbo

[talon77]

This is my first time posting on this forum. I just bought a used 2g exhaust manifold for a good price, but I noticed some dents (or deep scratches?) on the manifold flange where it meets the turbo. Check out the pics. Do you guys think that the surface imperfections will not cause a sealing problem since the metal gasket will fit the contours on the dents? Or do you think that I should take the manifold to a machine shop where I guess they'll fill the dents with weld and machine the surface flat? I have a stick feed mig welder, I don't have much welding experience, but I might consider filling the voids with weld myself and sanding it down... Is it worth it? What do you guys think? Thanks for the input.

 

[psychlow]

I would not try to do it yourself unless you only take material off. If you need to add material, take it to a good machine shop.

Welding cast iron is difficult because it is extremely sensitive. You have to use special welding wire, in combination with pre-heating the piece, welding while still hot, and cooling very slowly. Otherwise, your welds will crack right off when the manifold starts heat cycling a few times, and you may end up with trashed weld mowing down your turbine wheel.

 

[talon77]

I would not try to do it yourself unless you only take material off. If you need to add material, take it to a good machine shop.

Thanks psychlow, I think I will take your advice on that one and avoid repairing it myself. From the looks of it, do you think that I would have a sealing problem between the manifold and turbo if I installed it as is without taking it to machine shop? I know that the metal gasket will seal the two mating surfaces, but to what extent, just dunno...

 

[spades_gsx]

I would take it to a machine shop along with the turbine housing. that way your pretty much guarenteed not to get a leak. You could try to just slap it on but with the metal gasket you will have to re-torque the bolts for the first few heat cycles.

 

[talon77]

Thanks, I'm thinking that I will install the manifold as is and follow up with a few retorquings/heat cyclings. I'm sure if it leaks, there'll be a noise... I appreciate your responses!

 

[blue1]

Just make sure ther is no high spots from the dents smooth them down and you should be ok the dents dont lead to far out are you still using the fire ring?

 

[talon77]

Blue,
There aren't any high spots so I think that I should be alright I'm not planning to install the sealing ring, just the metal gasket. The metal gasket that I got from DSMotorsport has a small "ring" built into it (I know that it's not the same as the sealing ring insert), unlike the regular flat metal gaskets that I usually see. Anyways, as soon as I can get my hands untied, I'll install the manifold along with a b16g I just got with RnR 3"turboback... might be awhile though, but I'll keep you guys posted on my progress and whether or not the gasket seals. Thanks for the responses