Manifold repair

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A friend asked me to repair this manifold, said it got dropped and the end broke off. When I got to it I found that the end port was also cracked and very deteriorated. I got it cleaned up and tried to weld it with nomacast and the nickel, but it's too far gone. I'm going to try cast weld with the torch next, maybe tomorrow. Never done that before so any helpful advice would be appreciated.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Spent a lot of time with the dremel and grinder. Even had a piece fall out.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:Unless it's rare or something I'd just make something to replace that turd.Welding/Fab Pics: www.UtahWeld.com
Reply:Originally Posted by mikegyverunless it's rare or something i'd just make something to replace that turd.
Reply:Must be a very good friend to even consider fabbing a new one!30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Looks like a junkyard run and 10 bucks to me...why fix it?
Reply:When a manifold gets to that state it takes many hours and some machine work to patch it up, remember the areas not repaired are on the brink of failure. I usually prefer nife55 stick for economy, but if that didn't flow in then next is as you guessed- torch. Cast iron rod will be cheapest with powder spray quite a bit more expensive, I pay about 50 bucs a pound for nickel powder. I'd urge customer to replace, if that's not a option then get ready for expensive repair that will not have a long service period.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:He's been looking for a replacement for a long time and this is the best he could find. Besides I would like to try it just to see if I can do it, I've seen worse fixed before just not by me. It's for an antique tractor that won't get used much anyway.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw
Reply:I haven't ever tried to repair something like that, but I would think it would need to be bolted down to your table.  You might have to build some heavy brackets to make it line up right, and build a wooden box without a top or bottom.  Fill it with sand so you could preheat it and let it cool down slow.  I could also be way off base since I have never tried this.  It just seems like all the heat you are going to put into it is going to cause problems when it comes time to install the part.
Reply:Originally Posted by welderjHe's been looking for a replacement for a long time and this is the best he could find. Besides I would like to try it just to see if I can do it, I've seen worse fixed before just not by me. It's for an antique tractor that won't get used much anyway.
Reply:basically you want to make a half inch template to bolt it upto so it doesnt wander pull and warp different directions. considering that its cast i know the old timers used to braze cracks and splits etc. I have a friend who pre heats and just migs all his cast parts from heads, manifolds, blocks. Main thing is no mater how you decide to fuse join or what ever you need to have to bolted securely to a flat plate.if you can step across it I can weld it.